Section 1 General

CONTENTS
SECTION 1 GENERAL
Group 1 Safety Hints ------------------------------------------------------------------------------------------------------- 1-1

Group 2 Specifications ---------------------------------------------------------------------------------------------------- 1-10
SECTION 2 STRUCTURE AND FUNCTION
Group 1 Pump Device ----------------------------------------------------------------------------------------------------- 2-1

Group 2 Main Control Valve -------------------------------------------------------------------------------------------- 2-20
Group 3 Swing Device ---------------------------------------------------------------------------------------------------- 2-46
Group 4 Travel Device ----------------------------------------------------------------------------------------------------- 2-57
Group 5 RCV Lever --------------------------------------------------------------------------------------------------------- 2-66
Group 6 RCV Pedal --------------------------------------------------------------------------------------------------------- 2-73
SECTION 3 HYDRAULIC SYSTEM
Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------ 3-1

Group 2 Main Circuit -------------------------------------------------------------------------------------------------------- 3-3
Group 3 Pilot Circuit --------------------------------------------------------------------------------------------------------- 3-6
Group 4 Single Operation ----------------------------------------------------------------------------------------------- 3-14
Group 5 Combined Operation ---------------------------------------------------------------------------------------- 3-24
SECTION 4 ELECTRICAL SYSTEM
Group 1 Component Location ---------------------------------------------------------------------------------------- 4-1

Group 2 Electric Circuit --------------------------------------------------------------------------------------------------- 4-3
Group 3 Electrical Component Specification ---------------------------------------------------------------- 4-38
Group 4 Connectors ------------------------------------------------------------------------------------------------------- 4-46
SECTION 5 MECHATRONICS SYSTEM
Group 1 Outline --------------------------------------------------------------------------------------------------------------- 5-1

Group 2 Mode selection System ----------------------------------------------------------------------------------- 5-5
Group 3 Automatic Deceleration System --------------------------------------------------------------------- 5-11
Group 4 Power Boost System ---------------------------------------------------------------------------------------- 5-13
Group 5 Travel Speed Control System -------------------------------------------------------------------------- 5-15
Group 6 Automatic Warming Up Function -------------------------------------------------------------------- 5-17
Group 7 Engine Overheat Prevention Function ----------------------------------------------------------- 5-19
Group 8 Variable Power Control System ---------------------------------------------------------------------- 5-21
Group 9 Attachment Flow Control System ------------------------------------------------------------------- 5-22
Group 10 Anti-Restart System ----------------------------------------------------------------------------------------- 5-23
Group 11 Self-Diagnostic System ----------------------------------------------------------------------------------- 5-24
Group 12 Engine Control System ------------------------------------------------------------------------------------ 5-31
Group 13 EPPR (Electro Proportional Pressure Reducing) Valve ------------------------------- 5-33
Group 14 Monitoring System ------------------------------------------------------------------------------------------- 5-39
Group 15 Fuel Warmer System --------------------------------------------------------------------------------------- 5-71
SECTION 6 TROUBLESHOOTING
Group 1 Before Troubleshooting ------------------------------------------------------------------------------------ 6-1

Group 2 Hydraulic and Mechanical System ----------------------------------------------------------------- 6-4
Group 3 Electrical System ---------------------------------------------------------------------------------------------- 6-24
Group 4 Mechatronics System -------------------------------------------------------------------------------------- 6-56
SECTION 7 MAINTENANCE STANDARD
Group 1 Operational Performance Test ------------------------------------------------------------------------- 7-1

Group 2 Major Components ------------------------------------------------------------------------------------------- 7-23
Group 3 Track and Work Equipment ------------------------------------------------------------------------------ 7-32
SECTION 8 DISASSEMBLY AND ASSEMBLY
Group 1 Precaution --------------------------------------------------------------------------------------------------------- 8-1

Group 2 Tightening Torque --------------------------------------------------------------------------------------------- 8-4
Group 3 Pump Device ---------------------------------------------------------------------------------------------------- 8-7
Group 4 Main Control Valve ------------------------------------------------------------------------------------------- 8-30
Group 7 RCV Lever --------------------------------------------------------------------------------------------------------- 8-112
Group 8 Turning Joint ------------------------------------------------------------------------------------------------------ 8-126
Group 9 Boom, Arm and Bucket Cylinder -------------------------------------------------------------------- 8-131
Group 10 Undercarriage --------------------------------------------------------------------------------------------------- 8-148
Group 11 Work Equipment ----------------------------------------------------------------------------------------------- 8-160
SECTION 9 COMPONENT MOUNTING TORQUE
Group 1 Introduction guide --------------------------------------------------------------------------------------------- 9-1

Group 2 Engine system -------------------------------------------------------------------------------------------------- 9-2
Group 3 Electric system ------------------------------------------------------------------------------------------------- 9-4
Group 4 Hydraulic system ---------------------------------------------------------------------------------------------- 9-6
Group 6 Structure ------------------------------------------------------------------------------------------------------------ 9-11
Group 7 Work equipment ----------------------------------------------------------------------------------------------- 9-15
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to
perform repairs and make judgements. Make sure you understand the contents of this manual and
use it to full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
This section explains the hydraulic circuit, single and combined operation.
This section explains the electrical circuit, monitoring system and each component. It serves not
only to give an understanding electrical system, but also serves as reference material for trouble
shooting.
This section explains the computer aided power optimization system and each component.
This section explains the troubleshooting charts correlating problems to causes
causes.
This section gives the judgement standards when inspecting disassembled parts.
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
This section shows bolt specifications and standard torque values needed when mounting
components to the machine.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.
0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark
mark(①②③…)
Any additions, amendments or other changes will When a manual is revised, an edition mark is
be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the shop manual can be of ample
Example 1 practical use, important places for safety and
2-3 quality are marked with the following symbols.
Item number(2. Structure and
Function)
Consecutive page number for Symbol Item Remarks
each item.
Special safety precautions are
3. Additional pages : Additional pages are necessary when performing the
indicated by a hyphen(-) and number after the work.
Safety
page number. File as in the example. Extra special safety precautions
10 - 4 are necessary when performing
10 - 4 - 1 the work because it is under
Added pages internal pressure.
10 - 4 - 2
10 - 5 Special technical precautions or
※
other precautions for preserving
Caution
standards are necessary when
performing the work.
0-2
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
1. Method of using the Conversion Table to convert from millimeters to inches
Convert 55mm into inches.
(1) Locate the number 50in the vertical column at the left side, take this as ⓐ, then draw a
horizontal line from ⓐ.
(2) Locate the number 5in the row across the top, take this as ⓑ, then draw a perpendicular line
down from ⓑ.
(3) Take the point where the two lines cross as ⓒ. This point ⓒ gives the value when converting
from millimeters to inches. Therefore, 55mm = 2.165 inches.
2. Convert 550mm into inches.

(1) The number 550 does not appear in the table, so divide by 10(Move the decimal point one place
to the left) to convert it to 55mm.
(2) Carry out the same procedure as above to convert 55mm to 2.165 inches.
(3) The original value(550mm) was divided by 10, so multiply 2.165 inches by 10(Move the decimal
point one place to the right) to return to the original value.
This gives 550mm = 21.65 inches.
Millimeters to inches ⓑ
1mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
ⓒ
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
ⓐ
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
0-3
Millimeters to inches 1mm = 0.03937in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1kg = 2.2046lb
0 1 2 3 4 5 6 7 8 9
0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.5. 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
0-4
Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153
Liter to U.K. Gallon 1ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
0-5
kgf·m to lbf
kgf lbf·ftft 1kgf·m = 7.233lbf·ft
0 1 2 3 4 5 6 7 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
0-6
kgf/cm2 to lbf/in2 1kgf / cm2 = 14.2233lbf / in2
0 1 2 3 4 5 6 7 8 9
14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
0-7
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse
is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
˚C ˚F ˚C ˚F ˚C ˚F ˚C ˚F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 35 95.0 21.1 70 158.0 51.7 125 257.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 172 347.0
0-8
SECTION 1 GENERAL
Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1

Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10
SECTION 1 GENERAL
GROUP 1 SAFETY
FOLLOW SAFE PROCEDURE

Unsafe wor k practices are dangerous.
Understand service procedure before doing
work; Do not attempt shortcuts.
WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment
appropriate to the job.
13031GE01
WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause
serious injury.
Before performing any work on the excavator,
attach a 「DoDo Not Operate
Operate」 tag on the right
side control lever.
13031GE02
USE HANDHOLDS AND STEPS

Falling is one of the major causes of personal
injury.
When you get on and off the machine, always
maintain a three point contact with the steps
and handrails and face the machine. Do not
use any controls as handholds.
Never jump on or off the machine. Never mount
or dismount a moving machine. 13031GE03
Be careful of slippery conditions on platforms,

steps, and handrails when leaving the machine.
1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance ser vice, hospital, and fire
department near your telephone.
13031GE04
PROTECT AGAINST FLYING DEBRIS

Guard against injury from flying pieces of metal
or debris; Wear goggles or safety glasses.
13031GE05
PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective device such
as earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.
13031GE06
AVOID POWER LINES

Serious injury or death can result from contact
with electric lines.
Never move any part of the machine or load
closer to electric line than 3m(10ft) plus twice
the line insulator length.
13031GE07
1-2
KEEP RIDERS OFF EXCAVATOR
Only allow the operator on the excavator. Keep
riders off.
Riders on excavator are subject to injury such
as being struck by foreign objects and being
thrown off the excavator. Riders also obstruct
the operator's view resulting in the excavator
being operated in an unsafe manner.
13031GE08
MOVE AND OPERATE MACHINE SAFELY

Bystanders can be run over. Know the location
of bystanders before moving, swinging, or
operating the machine.
Always keep the travel alarm in working
condition. It warns people when the excavator
starts to move.
Use a signal person when moving, swinging, or 13031GE09
operating the machine in congested areas.
Coordinate hand signals before starting the
excavator.
OPERATE ONLY FORM OPERATOR'S SEAT

Avoid possible injury machine damage. Do not
star t engine by shor ting across star ter
terminals.
NEVER start engine while standing on ground.
Start engine only from operator's seat.
13031GE26
PARK MACHINE SAFELY

Before working on the machine:
·Park machine on a level surface.
·Lower bucket to the ground.
·Turn auto idle switch off.
·Run engine at 1/2 speed without load for 2 minutes.
·Turn key switch to OFF to stop engine. Remove key
from switch.
·Move pilot control shutoff lever to locked position.
·Allow engine to cool.
1-3
SUPPORT MACHINE PROPERLY
Always lower the attachment or implement to
the ground before you work on the machine. If
you must wor k on a lifted machine or
attachment, securely support the machine or
attachment.
Do not support the machine on cinder blocks,
hollow tiles, or props that may crumble under
13031GE10
continuous load.
Do not work under a machine that is supported
solely by a jack. Follow recommended
procedures in this manual.
SERVICE COOLING SYSTEM SAFELY

Explosive release of fluids from pressurized
cooling system can cause serious burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands.
13031GE11
HANDLE FLUIDS SAFELY-AVOID FIRES

Handle fuel with care; It is highly flammable.
Do not refuel the machine while smoking or
when near open flame or sparks. Always stop
engine before refueling machine.
Fill fuel tank outdoors.
13031GE12
Store flammable fluids away from fire hazards.

Do not incinerate or puncture pressurized
containers.
Make sure machine is clean of trash,
grease, and debris.
Do not store oily rags; They can ignite and
burn spontaneously.
13031GE13
1-4
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes
can cause sickness or death.
If you must operate in a building, be positive
there is adequate ventilation. Either use an
exhaust pipe extension to remove the exhaust
fumes or open doors and windows to bring
enough outside air into the area.
REMOVE PAINT BEFORE WELDING OR
HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint
is heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
· If you sand or grind paint, avoid breathing the 13031GE14
dust.
Wear an approved respirator.
·If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area.
Allow fumes to disperse at least 15 minutes
before welding or heating.
ILLUMINATE WORK AREA SAFELY

Illuminate your work area adequately but safely.
Use a portable safety light for working inside or
under the machine. Make sure the bulb is
enclosed by a wire cage. The hot filament of
an accidentally broken bulb can ignite spilled
fuel or oil.
13031GE15
1-5
SERVICE MACHINE SAFELY
Tie long hair behind your head. Do not wear a
necktie, scarf, loose clothing or necklace when
you work near machine tools or moving parts.
If these items were to get caught, severe injury
could result.
Remove rings and other jewelry to prevent
electrical shorts and entanglement in moving
13031GE16
parts.
STAY CLEAR OF MOVING PARTS

Entanglements in moving parts can cause
serious injury.
To prevent accidents, use care when working
around rotating parts.
13031GE17
AVOID HIGH PRESSURE FLUIDS

Escaping fluid under pressure can penetrate the
skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure 13031GE18
fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result.
13031GE19
1-6
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating
near pressurized fluid lines, resulting in severe
burns to yourself and bystanders. Do not heat
by welding, soldering, or using a torch near
pressurized fluid lines or other flammable
materials.
13031GE20
Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.
Install fire resisting guards to protect hoses or
other materials.
PREVENT BATTERY EXPLOSIONS

Keep sparks, lighted matches, and flame away
from the top of battery. Battery gas can
explode.
Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; It may explode.
Warm battery to 16˚C (60˚F ). 13031GE21
1-7
PREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte
is added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10-15
minutes. Get medical attention immediate-
ly. 13031GE22
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs,
or vegetable oil.
3. Get medical attention immediately.
USE TOOLS PROPERLY

Use tools appropriate to the work. Makeshift
tools, parts, and procedures can create safety
hazards.
Use power tools only to loosen threaded tools
and fasteners.
For loosening and tightening hardware, use the
correct size tools. DO NOT use U.S.
measurement tools on metric fasteners. Avoid
bodily injury caused by slipping wrenches. 13031GE23
Use only recommended replacement parts.

(See Parts catalogue.)
1-8
DISPOSE OF FLUIDS PROPERLY
Improperly disposing of fluids can harm the
environment and ecology. Before draining any
fluids, find out the proper way to dispose of
waste from your local environmental agency.
Use proper containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from them.
DO NOT pour oil into the ground, down a drain,
or into a stream, pond, or lake. Observe 13031GE24
relevant environmental protection regulations
when disposing of oil, fuel, coolant, brake fluid,
filters, batteries, and other harmful waste.
REPLACE SAFETY SIGNS

Replace missing or damaged safety signs.
See the machine operator's manual for correct
safety sign placement.
13031GE25
LIVE WITH SAFETY

Before returning machine to customer, make
sure machine is functioning properly, especially
the safety systems. Install all guards and
shields.
1-9
GROUP 2 SPECIFICATIONS
1. MAJOR COMPONENT
Battery box Fuel tank Hydraulic tank Main pump
Engine
Oil cooler
Tooth Bucket Turning joint Swing motor Main control valve Radiator
Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight
Bucket cylinder Connecting link Idler Carrier roller Sprocket
Side cutter Connecting rod

Connecting rod Track roller Track Travel motor
3309S2SP01
1-10
2. SPECIFICATIONS
1) R330LC-9S
·6.45
6.45 m (21' 2") BOOM and 3.20 m (10' 6") ARM
I(I') D
C
E
G
F
H
J M
K N
A B(L)
3309S2SP02
Description Unit Specification

Operating weight kg (lb) 32700 (72090)
Bucket capacity (SAE heaped), standard m (yd )
3 3 1.44 (1.88)
Overall length A 10980 (36' 0")
Overall width, with 600 mm shoe B 3280 (10' 9")
Overall height C 3380 (11' 1")
Superstructure width D 2980 ( 9' 9")
Overall height of cab E 3090 (10' 2")
Ground clearance of counterweight F 1200 ( 3' 11")
Engine cover height G 2580 ( 8' 6")
Minimum ground clearance H mm (ft-in) 500 ( 1' 8")
Rear-end distance I 3265 (10' 9")
Rear-end swing radius I' 3330 (10' 11")
Distance between tumblers J 4030 (13' 3")
Undercarriage length K 4940 (16' 2")
Undercarriage width L 3280 (10' 9")
Track gauge M 2680 ( 8' 10")
Track shoe width, standard N 600 (24")
Travel speed (low/high) km/hr (mph) 3.3/5.8 (2.1/3.6)
Swing speed rpm 9.5
Gradeability Degree (%) 35 (70)
Ground pressure (600 mm shoe) kgf/cm2(psi) 0.63 (8.96)
Max traction force kg (lb) 29500 (65040)
1-11
2) R330NLC-9S
·6.45
6.45 m (21' 2") BOOM and 3.20 m (10' 6") ARM
I(I') D
C
E
G
F
H
J M
K N
A B(L)
3309S2SP03

Bucket capacity (SAE heaped), standard m3 (yd3) 1.44 (1.88)
Overall width, with 600 mm shoe B 2990 ( 9' 10")
Undercarriage width L 2990 ( 9' 10")
Track gauge M 2390 ( 7' 10")
Swing speed rpm 9.5
1-12
3) R330LC-9S HIGH WALKER
·6.45
6.45 m (21' 2") BOOM and 3.20 m (10' 6") ARM
I(I') D
E
C
G
F
H
J M
K N
A B(L)
3309S2SP04

Bucket capacity (SAE heaped), standard m3 (yd3) 1.44 (1.88)
Overall width, with 600 mm shoe B 3470 (11' 5")
Undercarriage width L 3470 (11' 5")
Track gauge M 2870 ( 9' 5")
Swing speed rpm 9.5
1-13
3. WORKING RANGE
1) R330LC-9S, R330NLC-9S
A
A'
F
D
B' E
C
B
8ft
32092SP05
6.45 m (21' 2") Arm 6.15 m (20' 2") Boom

Description
2.2 m (7' 3") Arm 2.5 m (8' 2") Arm 3.2 m (10' 6") Arm 4.05 m (13' 3") Arm 2.2 m (7' 3") Arm
Max digging reach A 10330 mm (33'11") 10550 mm (34' 7") 11140 mm (36' 7") 11950 mm (39' 2") 10020 mm (32'10")
Max digging reach on ground A' 10110 mm (33' 2") 10330 mm (33'11") 10940 mm (35'11") 11760 mm (38' 7") 9800 mm (32' 2")
Max digging depth B 6370 mm (20'11") 6670 mm (21'11") 7370 mm (24' 2") 8220 mm (27' 0") 6160 mm (20' 3")
Max digging depth (8ft level) B' 6160 mm (20' 3") 6470 mm (21' 3") 7210 mm (23' 8") 8080 mm (26' 6") 5950 mm (19' 6")
Max vertical wall digging depth C 5980 mm (19' 7") 5920 mm (19' 5") 6360 mm (20'10") 7260 mm (23'10") 5710 mm (18' 9")
Max digging height D 10220 mm (33' 6") 10170 mm (33' 4") 10310 mm (33'10") 10710 mm (35' 2") 9940 mm (32' 7")
Max dumping height E 7050 mm (23' 2") 7050 mm (23' 2") 7240 mm (23' 9") 7630 mm (25' 0") 6780 mm (22' 3")
Min swing radius F 4700 mm (15' 5") 4500 mm (14' 9") 4470 mm (14' 8") 4470 mm (14' 8") 4520 mm (14'10")
189.3 [205.5] kN 189.3 [205.5] kN 189.3 [205.5] kN 189.3 [205.5] kN 189.3 [205.5] kN
SAE 19300 [20950] kgf 19300 [20950] kgf 19300 [20950] kgf 19300 [20950] kgf 19300 [20950] kgf
42550 [46200] lbf 42550 [46200] lbf 42550 [46200] lbf 42550 [46200] lbf 42550 [46200] lbf
Bucket digging force
211.8 [230.0] kN 211.8 [230.0] kN 211.8 [230.0] kN 211.8 [230.0] kN 211.8 [230.0] kN
ISO 21600 [23450] kgf 21600 [23450] kgf 21600 [23450] kgf 21600 [23450] kgf 21600 [23450] kgf
196.6 [213.4] kN 178.9 [194.2] kN 143.2 [155.5] kN 119.6 [129.9] kN 196.6 [213.4] kN
Arm crowd force
202.8 [220.2] kN 185.1 [201.0] kN 147.1 [159.7] kN 122.7 [133.3] kN 202.8 [220.2] kN
[ ] : Power boost
1-14
A
A'
F
D
B' E
C
B
8ft
32092SP06
6.45 m (21' 2") Arm 6.15 m (20' 2") Boom

Description
2.2 m (7' 3") Arm 2.5 m (8' 2") Arm 3.2 m (10' 6") Arm 4.05 m (13' 3") Arm 2.2 m (7' 3") Arm
Max digging reach A 10330 mm (33'11") 10550 mm (34' 7") 11140 mm (36' 7") 11950 mm (39' 2") 10020 mm (32'10")
Max digging reach on ground A' 10040 mm (32'11") 10270 mm (33' 8") 10880 mm (35' 8") 11710 mm (38' 5") 9730 mm (31'11")
Max digging depth B 6100 mm (20' 0") 6400 mm (21' 0") 7100 mm (23' 4") 7950 mm (26' 1") 5880 mm (19' 3")
Max digging depth (8ft level) B' 5890 mm (19' 4") 6200 mm (20' 4") 6940 mm (22' 9") 7800 mm (25' 7") 5680 mm (18' 8")
Max vertical wall digging depth C 5700 mm (18' 8") 5650 mm (18' 6") 6080 mm (19'11") 6980 mm (22'11") 5440 mm (17'10")
Max digging height D 10500 mm (34' 5") 10450 mm (34' 3") 10590 mm (34' 9") 10990 mm (36' 1") 10220 mm (33' 6")
Max dumping height E 7330 mm (24' 1") 7330 mm (24' 1") 7520 mm (24' 8") 7910 mm (25'11") 7060 mm (23' 2")
Min swing radius F 4700 mm (15' 5") 4500 mm (14' 9") 4470 mm (14' 8") 4470 mm (14' 8") 4520 mm (14'10")
189.3 [205.5] kN 189.3 [205.5] kN 189.3 [205.5] kN 189.3 [205.5] kN 189.3 [205.5] kN
Bucket digging force
211.8 [230.0] kN 211.8 [230.0] kN 211.8 [230.0] kN 211.8 [230.0] kN 211.8 [230.0] kN
196.6 [213.4] kN 178.9 [194.2] kN 143.2 [155.5] kN 119.6 [129.9] kN 196.6 [213.4] kN
Arm crowd force
202.8 [220.2] kN 185.1 [201.0] kN 147.1 [159.7] kN 122.7 [133.3] kN 202.8 [220.2] kN
[ ] : Power boost
1-15
4. WEIGHT
1) R330LC-9S, R330NLC-9S
R330LC-9S R330NLC-9S
Item
kg lb kg lb
Upperstructure assembly 14390 31720 ą ą
Main frame weld assembly 3760 8290 ą ą
Engine assembly 620 1370 ą ą
Main pump assembly 200 440 ą ą
Main control valve assembly 220 490 ą ą
Swing motor assembly 370 820 ą ą
Hydraulic oil tank assembly 230 490 ą ą
Fuel tank assembly 210 450 ą ą
Counterweight 6200 13670 ą ą
Cab assembly 490 1080 ą ą
Radiator total assy 280 620 ą ą
Lower chassis assembly 11500 25770 11360 25040
Track frame weld assembly 3970 8750 3835 8450
Swing bearing 410 900 ą ą
Travel motor assembly 360 800 ą ą
Turning joint 50 110 ą ą
Tension cylinder 210 450 ą ą
Idler 250 540 ą ą
Sprocket 80 170 ą ą
Carrier roller 40 80 ą ą
Track roller 60 120 ą ą
Track-chain assembly (600 mm standard triple grouser shoe) 1860 4100 ą ą
Front attachment assembly (6.45 m boom, 3.2 m arm,
6390 14090 ą ą
1.44 m3 SAE heaped bucket)
6.45 m boom assembly 2540 5600 ą ą
3.2 m arm assembly 1160 2560 ą ą
1.44 m SAE heaped bucket
3 1120 2470 ą ą
Boom cylinder assembly 300 660 ą ą
Arm cylinder assembly 380 840 ą ą
Bucket cylinder assembly 270 570 ą ą
Bucket control linkage assembly 370 820 ą ą
1-16
Item kg lb
Upperstructure assembly 14790 32600

Main frame weld assembly 3760 8290
Engine assembly 620 1370
Main pump assembly 200 440
Main control valve assembly 220 490
Swing motor assembly 370 820
Hydraulic oil tank assembly 230 490
Fuel tank assembly 210 450
Counterweight 6600 14550
Cab assembly 490 1080
Radiator total assy 280 620
Lower chassis assembly 14000 30860
Track frame weld assembly 6180 13620
Swing bearing 410 900
Travel motor assembly 360 800
Turning joint 50 110
Tension cylinder 210 450
Idler 250 540
Sprocket 80 170
Carrier roller 40 80
Track roller 60 120
Track-chain assembly (600 mm standard triple grouser shoe) 1860 4100
Front attachment assembly (6.45 m boom, 3.2 m arm,
6390 14090
1.44 m3 SAE heaped bucket)
6.45 m boom assembly 2540 5600
3.2 m arm assembly 1160 2560
1.44 m3SAE heaped bucket 1120 2470
Boom cylinder assembly 300 660
Arm cylinder assembly 380 840
Bucket cylinder assembly 270 570
Bucket control linkage assembly 370 820
1-17
5. LIFTING CAPACITIES
1) R330LC-9S
(1) 6.15 m (20' 2") boom, 2.2 m (7' 3") arm equipped with 1.44 m3 (SAE heaped) bucket and 600 mm
(24") triple grouser shoe.
Â : Rating over-front Â : Rating over-side or 360 degree
Load radius At max. reach

Load point 3.0 m (10.0 ft) 4.5 m (15.0 ft) 6.0m (20.0 ft) 7.5 m (25.0 ft) Capacity Reach
height
m (ft)
7.5 m kg *7480 5800 7.69
(25.0 ft) lb *16490 12790 (25.2)
6.0 m kg *8380 *8380 *8070 5900 7160 4610 8.61
(20.0 ft) lb *18470 *18470 *17790 13010 15790 10160 (28.2)
4.5 m kg *12080 *12080 *9630 8430 *8490 5760 6330 4020 9.16
(15.0 ft) lb *26630 *26630 *21230 18580 *18720 12700 13960 8860 (30.1)
3.0 m kg *15590 12350 *11230 7930 8690 5530 5960 3740 9.39
(10.0 ft) lb *34370 27230 *24760 17480 19160 12190 13140 8250 (30.8)
1.5 m kg *18040 11560 12140 7500 8450 5310 5930 3710 9.35
(5.0 ft) lb *39770 25490 26760 16530 18630 11710 13070 8180 (30.7)
Ground kg *18760 11280 11850 7250 8280 5160 6250 3910 9.02
Line lb *41360 24870 26120 15980 18250 11380 13780 8620 (29.6)
-1.5 m kg *16910 *16910 *18280 11280 11760 7170 8240 5130 7070 4450 8.37
(-5.0 ft) lb *37280 *37280 *40300 24870 25930 15810 18170 11310 15590 9810 (27.5)
-3.0 m kg *22970 *22970 *16680 11470 11870 7270 *8360 5670 7.29
(-10 ft) lb *50640 *50640 *36770 25290 26170 16030 *18430 12500 (23.9)
-4.5 m kg *17920 *17920 *13190 11900
(-15.0 ft) lb *39510 *39510 *29080 26230
Note 1. Lifting capacity are based on SAE J1097 and ISO 10567.
2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine
on firm, level ground or 87% of full hydraulic capacity.
3. The load point is a hook located on the back of the bucket.
4. *indicates load limited by hydraulic capacity.
1-18
Load
1.5 m (5.0 ft) 3.0 m (10.0 ft) 4.5 m (15.0 ft) 6.0 m (20.0 ft) 7.5 m (25.0 ft) 9.0 m (30.0 ft) Capacity Reach
point
height m (ft)
7.5 m kg *5240 *5240 *5970 4280 9.06
(25.0 ft) lb *11550 *11550 *13160 9440 (29.7)
6.0 m kg *6500 5990 5630 3540 9.84
(20.0 ft) lb *14330 13210 12410 7800 (32.3)
4.5 m kg *8090 *8090 *7190 5740 *5440 4060 5070 3130 10.31
(15.0 ft) lb *17840 *17840 *15850 12650 *11990 8950 11180 6900 (33.8)
3.0 m kg *13400 12410 *9820 7840 *8110 5420 6270 3910 4790 2920 10.52
(10.0 ft) lb *29540 27360 *21650 17280 *17880 11950 13820 8620 10560 6440 (34.5)
1.5 m kg *16400 11330 *11460 7290 8260 5120 6100 3750 4740 2860 10.48
(5.0 ft) lb *36160 24980 *25260 16070 18210 11290 13450 8270 10450 6310 (34.4)
Ground kg *10240 *10240 *17910 10800 11500 6920 8000 4890 5960 3620 4920 2970 10.19
Line lb *22580 *22580 *39480 23810 25350 15260 17640 10780 13140 7980 10850 6550 (33.4)
-1.5 m kg *11380 *11380 *14470 *14470 *18150 10650 11300 6740 7870 4760 5400 3270 9.63
(-5.0 ft) lb *25090 *25090 *31900 *31900 *40010 23480 24910 14860 17350 10490 11900 7210 (31.6)
-3.0 m kg *15350 *15350 *19470 *19470 *17370 10730 11300 6740 7880 4770 6380 3920 8.74
(-10.0 ft) lb *33840 *33840 *42920 *42920 *38290 23660 24910 14860 17370 10520 14070 8640 (28.7)
-4.5 m kg *21820 *21820 *15410 11010 *11230 6920 *7480 5360 7.37
(-15.0 ft) lb *48100 *48100 *33970 24270 *25200 15260 *16490 11820 (24.2)
-6.0 m kg *11340 *11340
(-20.0 ft) lb *25000 *25000
1-19
2) R330NLC-9S

height
m (ft)
7.5 m kg *7480 4910 7.69
(25.0 ft) lb *16490 10820 (25.2)
6.0 m kg *8380 7500 *8070 4970 7120 3860 8.61
(20.0 ft) lb *18470 16530 *17790 10960 15700 8510 (28.2)
4.5 m kg *12080 11320 *9630 7110 *8490 4840 6280 3330 9.16
(15.0 ft) lb *26630 24960 *21230 15670 *18720 10670 13850 7340 (30.1)
3.0 m kg *15590 10200 *11230 6630 8640 4620 5910 3080 9.39
(10.0 ft) lb *34370 22490 *24760 14620 19050 10190 13030 6790 (30.8)
1.5 m kg *18040 9460 12060 6220 8390 4400 5880 3040 9.35
(5.0 ft) lb *39770 20860 26590 13710 18500 9700 12960 6700 (30.7)
Ground kg *18760 9200 11770 5980 8230 4260 6200 3210 9.02
Line lb *41360 20280 25950 13180 18140 9390 13670 7080 (29.6)
-1.5 m kg *16910 *16910 *18280 9190 11680 5910 8190 4220 7030 3670 8.37
(-5.0 ft) lb *37280 *37280 *40300 20260 25750 13030 18060 9300 15500 8090 (27.5)
-3.0 m kg *22970 18930 *16680 9370 11800 6000 *8360 4720 7.29
(-10 ft) lb *50640 41730 *36770 20660 26010 13230 *18430 10410 (23.9)
-4.5 m kg *17920 *17920 *13190 9770
(-15.0 ft) lb *39510 *39510 *29080 21540
1-20
Load
point
height m (ft)
7.5 m kg *5240 5170 *5970 3580 9.06
(25.0 ft) lb *11550 11400 *13160 7890 (29.7)
6.0 m kg *6500 5060 5590 2920 9.84
(20.0 ft) lb *14330 11160 12320 6440 (32.3)
4.5 m kg *8090 7130 *7190 4810 *5440 3360 5030 2540 10.31
(15.0 ft) lb *17840 15720 *15850 10600 *11990 7410 11090 5600 (33.8)
3.0 m kg *13400 10240 *9820 6540 *8110 4510 6230 3210 4760 2350 10.52
(10.0 ft) lb *29540 22580 *21650 14420 *17880 9940 13730 7080 10490 5180 (34.5)
1.5 m kg *16400 9230 *11460 6010 8200 4210 6050 3050 4710 2290 10.48
(5.0 ft) lb *36160 20350 *25260 13250 18080 9280 13340 6720 10380 5050 (34.4)
Ground kg *10240 *10240 *17910 8730 11420 5650 7950 3990 5920 2930 4880 2380 10.19
Line lb *22580 *22580 *39480 19250 25180 12460 17530 8800 13050 6460 10760 5250 (33.4)
-1.5 m kg *11380 *11380 *14470 *14470 *18150 8590 11220 5480 7810 3870 5360 2640 9.63
(-5.0 ft) lb *25090 *25090 *31900 *31900 *40010 18940 24740 12080 17220 8530 11820 5820 (31.6)
-3.0 m kg *15350 *15350 *19470 17640 *17370 8660 11220 5480 7820 3880 6340 3190 8.74
(-10.0 ft) lb *33840 *33840 *42920 38890 *38290 19090 24740 12080 17240 8550 13980 7030 (28.7)
-4.5 m kg *21820 18170 *15410 8930 *11430 5660 *7480 4430 7.37
(-15.0 ft) lb *48100 40060 *33970 19690 *25200 12480 *16490 9770 (24.2)
-6.0 m kg *11340 9470
(-20.0 ft) lb *25000 20880
1-21

height
m (ft)
7.5 m kg *7480 6400 7.90
(25.0 ft) lb *16490 14110 (25.9)
6.0 m kg *8560 *8560 *8100 6850 *7570 5250 8.74
(20.0 ft) lb *18870 *18870 *17860 15100 *16690 11570 (28.7)
4.5 m kg *12730 *12730 *9910 9670 *8620 6680 6870 4670 9.22
(15.0 ft) lb *28060 *28060 *21850 21320 *19000 14730 15150 10300 (30.2)
3.0 m kg *16170 14300 *11520 9170 *9400 6440 6550 4420 9.40
(10.0 ft) lb *35650 31530 *25400 20220 *20720 14200 14440 9740 (30.8)
1.5 m kg *18290 13590 *12850 8760 9250 6230 6590 4440 9.31
(5.0 ft) lb *40320 29960 *28330 19310 20390 13730 14530 9790 (30.5)
Ground kg *18750 13380 12960 8530 9100 6100 7020 4730 8.93
Line lb *41340 29500 28570 18810 20060 13450 15480 10430 (29.3)
-1.5 m kg *18620 *18620 *18070 13410 12910 8490 9090 6090 8060 5450 8.21
(-5.0 ft) lb *41050 *41050 *39840 29560 28460 18720 20040 13430 17770 12020 (26.9)
-3.0 m kg *22250 *22250 *16210 13640 *12030 8630 *8240 7100 7.03
(-10 ft) lb *49050 *49050 *35740 30070 *26520 19030 *18170 15650 (23.1)
-4.5 m kg *12130 *12130
(-15.0 ft) lb *26740 *26740
1-22
Load
point
height m (ft)
7.5 m kg *5730 *5730 *5990 4840 9.24
(25.0 ft) lb *12630 *12630 *13210 10670 (30.3)
6.0 m kg *6600 *6600 6100 4100 9.95
(20.0 ft) lb *14550 *14550 13450 9040 (32.6)
4.5 m kg *8400 *8400 *7350 6650 *5820 4790 5570 3700 10.37
(15.0 ft) lb *18520 *18520 *16200 14660 *12830 10560 12280 8160 (34.0)
3.0 m kg *14050 *14050 *10150 9060 *8290 6320 6920 4620 5330 3500 10.53
(10.0 ft) lb *30970 *30970 *22380 19970 *18280 13930 15260 10190 11750 7720 (34.5)
1.5 m kg *16800 13300 *11720 8530 9070 6020 6750 4460 5320 3480 10.45
(5.0 ft) lb *37040 29320 *25840 18810 20000 13270 14880 9830 11730 7670 (34.3)
Ground kg *10990 *10990 *18040 12850 12640 8180 8840 5810 6630 4350 5570 3650 10.11
Line lb *24230 *24230 *39770 28330 27870 18030 19490 12810 14620 9590 12280 8050 (33.2)
-1.5 m kg *12090 *12090 *15330 *15330 *18080 12750 12480 8040 8730 5700 6170 4060 9.50
(-5.0 ft) lb *26650 *26650 *33800 *33800 *39860 28110 27510 17730 19250 12570 13600 8950 (31.2)
-3.0 m kg *16150 *16150 *20540 *20540 *17110 12870 12510 8070 8770 5740 7390 4910 8.53
(-10.0 ft) lb *35600 *35600 *45280 *45280 *37720 28370 27580 17790 19330 12650 16290 10820 (28.0)
-4.5 m kg *20940 *20940 *14870 13200 *10980 8300 *7390 6870 7.03
(-15.0 ft) lb *46160 *46160 *32780 29100 *24210 18300 *16290 15150 (23.1)
1-23
6. BUCKET SELECTION GUIDE
1) GENERAL BUCKET
0.9 m3 SAE 1.14 m3 SAE 1.44 m3 SAE 1.74 m3 SAE 2.10 m3 SAE
heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket
Recommendation
Capacity Width 6.15 m (20' 2")
6.45 m (21' 2") boom
Weight boom
SAE CECE Without With 2.2 m arm 2.5 m arm 3.2 m arm 4.05 m arm 2.2 m arm
heaped heaped side cutter side cutter (7' 3") (8' 2") (10' 6") (13' 3") (7' 3")
0.9 m3 0.8 m3 950 mm 1070 mm 870 kg

(1.18 yd3) (1.05 yd3) (37.4") (42.1") (1920 lb)
1.14 m3 1.0 m3 1110 mm 1230 mm 980 kg

(1.49 yd3) (1.31 yd3) (43.7") (48.4") (2160 lb)
1.44 m3 1.25 m3 1380 mm 1500 mm 1110 kg

(1.88 yd3) (1.63 yd3) (54.3") (59.1") (2450 lb
1.74 m3 1.5 m3 1620 mm 1740 mm 1230 kg

(2.28 yd3) (1.96 yd3) (63.8") (68.5") (2710 lb)
2.10 m3 1.8 m3 1910 mm 2030 mm 1370 kg

(2.75 yd3) (2.35 yd3) (75.2") (79.9") (3020 lb)
Applicable for materials with density of 2000 kg/m3 (3370 lb/yd3) or less
1-24
2) ROCK AND HEAVY DUTY BUCKET
Ľ1.44 m3 SAE
ľ1.44 m3 SAE
Ľ1.73 m3 SAE
heaped bucket
heaped bucket
Recommendation
Capacity Width 6.15 m (20' 2")
6.45 m (21' 2") boom
Weight boom
SAE CECE Without With 2.2 m arm 2.5 m arm 3.2 m arm 4.05 m arm 2.2 m arm
heaped heaped side cutter side cutter (7' 3") (8' 2") (10' 6") (13' 3") (7' 3")
ľ1.44 m3 1.25 m3 1470 mm 1380 kg

-
(1.88 yd3) (1.63 yd3) (57.9") (3040 lb)
Ľ1.44 m3 1.25 m3 1470 mm 1470 kg

-
(1.88 yd3) (1.63 yd3) (57.9") (3240 lb)
Ľ1.73 m3 1.5 m3 1710 mm 1610 kg

-
(2.26 yd3) (1.96 yd3) (67.3") (3550 lb)
ľ: Heavy duty bucket

Ľ: Rock-Heavy duty bucket
1-25
7. UNDERCARRIAGE
1) TRACKS
X-leg type center frame is integrally welded with reinforced box-section track frames. The design
includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock
absorbing springs and assembled track-type tractor shoes with triple grousers.
2) TYPES OF SHOES
Triple grouser
Model Shapes
Shoe width mm (in) 600(24) 700(28) 800(32) 900(36)

Operating weight kg (lb) 32700(72090) 33280(73410) 33640(74300) 34040(75180)
R330LC-9S
Ground pressure kgf/cm2 (psi) 0.63(8.96) 0.55(7.82) 0.48(6.83) 0.44(6.26)
Overall width mm (ft-in) 3280(10' 9") 3380(11' 1") 3480(11' 5") 3580(11' 9")
Shoe width mm (in) 600(24) - - -
Operating weight kg (lb) 32500(71650) - - -
R330NLC-9S
Ground pressure kgf/cm2 (psi) 0.62(8.82) - - -
Overall width mm (ft-in) 2990(9' 10") - - -
Shoe width mm (in) 600(24) 700(28) 800(32) Double Grouser
710(28)
R330LC-9S Operating weight kg (lb) 35200(77600) 35800(78920) 36200(79810) 36680(80690)
HIGH WALKER Ground pressure kgf/cm2 (psi) 0.68(9.67) 0.59(8.39) 0.52(7.39) 0.47(6.68)
Overall width mm (ft-in) 3470(11' 5") 3570(11' 9") 3670(12' 0") 3580(11' 9")
3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE

Item Quantity
Carrier rollers 2EA
Track rollers 9EA
Track shoes 48EA
1-26
4) SELECTION OF TRACK SHOE
Suitable track shoes should be selected according to operating conditions.
Method of selecting shoes
Confirm the category from the list of applications in table 2 2, then use table 1 to select the shoe.
Wide shoes (categories B and C) have limitations on applications. Before using wide shoes,
check the precautions, then investigate and study the operating conditions to confirm if these
shoes are suitable.
Select the narrowest shoe possible to meet the required flotation and ground pressure. Application
of wider shoes than recommendations will cause unexpected problem such as bending of shoes,
crack of link, breakage of pin, loosening of shoe bolts and the other various problems.
öTable
Table 1
Track shoe Specification Category
600 mm triple grouser Standard A
700 mm triple grouser Option B
710 mm double grouser Option B
800 mm triple grouser Option C
900 mm triple grouser Option C
öTable
Table 2
Category Applications Applications
Rocky ground, Â Travel at low speed on rough ground with large obstacles such as
A river beds, boulders or fallen trees
normal soil
Normal soil, Â These shoes cannot be used on rough ground with large obstacles such
soft ground as boulders or fallen trees
B
Â Travel at high speed only on flat ground
Â Travel slowly at low speed if it is impossible to avoid going over obstacles
Extremely soft gound Â Use the shoes only in the conditions that the machine sinks and it is
(swampy ground) impossible to use the shoes of category A or B
Â These shoes cannot be used on rough ground with large obstacles such
C
as boulders or fallen trees
Â Travel at high speed only on flat ground
Â Travel slowly at low speed if it is impossible to avoid going over obstacles
1-27
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins C8.3-C
Type 4-cycle turbocharged charger air cooled diesel engine
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder boreÝstroke 114Ý135 mm (4.49"Ý5.32")
Piston displacement 8300 cc (506 cu in)
Compression ratio 18 : 1
Rated gross horse power (SAE J1995) 259 Hp at 1750 rpm (193 kW at 1750 rpm)
Maximum torque 124.3 kgfÂm (899 lbfÂft) at 1300 rpm
Engine oil quantity 25.5˶(6.7 U.S. gal)
Dry weight 620 kg (1367 lb)
High idling speed 195050 rpm
Low idling speed 850Ü50 rpm
Rated fuel consumption 155.5 g/HpÂhr at 1750 rpm
Starting motor 24V-7.5 kW
Alternator 24V-70A
Battery 2Ý12VÝ160Ah
2) MAIN PUMP
Item Specification
Type Variable displacement tandem axis piston pumps
Capacity 2Ý148.6 cc/rev
Rated oil flow 2Ý282˶/min (74.5 U.S. gpm / 62.0 U.K. gpm)
Rated speed 1900 rpm
1-28
3) GEAR PUMP
Item Specification
Type Fixed displacement gear pump single stage
Capacity 15cc/rev
Maximum pressure 40 kgf/cm2 (570 psi)
Rated oil flow 28.5˶/min (7.5 U.S. gpm/6.3 U.K. gpm)
4) MAIN CONTROL VALVE

Item Specification
Type 9 spools
Operating method Hydraulic pilot system
Main relief valve pressure 350 kgf/cm2 (4980 psi) [380 kgf/cm2 (5400 psi)]
Overload relief valve pressure 400 kgf/cm2 (5690 psi)
[ ]: Power boost
5) SWING MOTOR
Item Specification
Type Axial piston motor
Capacity 169.4 cc/rev
Relief pressure 300 kgf/cm2 (4270 psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 70 kgfÂm (505 lbfÂft)
Brake release pressure 26 kgf/cm2 (370 psi)
Reduction gear type 2 - stage planetary
6) TRAVEL MOTOR
Item Specification
Type Variable displacement bent-axis axial piston motor
Relief pressure 350 kgf/cm2 (4980 psi)
Capacity (max / min) 154.8/88.5 cc/rev
Reduction gear type 3-stage planetary
Braking system Automatic, spring applied hydraulic released
Brake release pressure 9 kgf/cm2 (128 psi)
Braking torque 40 kgfÂm (290 lbfÂft)
1-29
7) REMOTE CONTROL VALVE
Item Specification
Type Pressure reducing type
Minimum 6.5 kg/cm2 (92 psi)
Operating pressure
Maximum 26 kg/cm2 (370 psi)
Lever 61 mm (2.4 in)
Single operation stroke
Pedal 123 mm (4.84 in)
8) CYLINDER
Item Specification
Bore diaÝRod diaÝStroke ͚150Ý͚105Ý1480 mm
Boom cylinder
Cushion Extend only
Arm cylinder
Cushion Extend and retract
Bucket cylinder
Cushion Extend only
ö Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on
the rod surface.
ö Discoloration does not cause any harmful effect on the cylinder performance.
9) SHOE
Item Width Ground pressure Link quantity Overall width
Standard ÷600 mm (24") 0.63 kgf/cm2 (8.96 psi) 48 3280 mm (10' 9")
÷700 mm (28") 0.55 kgf/cm2 (7.82 psi) 48 3380 mm (11' 1")
R330LC-9S
Option ÷800 mm (32") 0.48 kgf/cm2 (6.83 psi) 48 3480 mm (11' 5")
÷900 mm (36") 0.44 kgf/cm2 (6.26 psi) 48 3580 mm (11' 9")
R330NLC-9S Standard ÷600 mm (24") 0.62 kgf/cm2 (8.82 psi) 48 2990 mm ( 9' 10")
Standard ÷600 mm (24") 0.68 kgf/cm2 (9.67 psi) 48 3470 mm (11' 5")
R330LC-9S ÷700 mm (28") 0.59 kgf/cm2 (8.39 psi) 48 3570 mm (11' 9")
H/WALKER Option ÷800 mm (32") 0.52 kgf/cm2 (7.39 psi) 48 3670 mm (12' 0")
ø710 mm (28") 0.47 kgf/cm2 (6.68 psi) 48 3580 mm (11' 9")
÷: Triple grouser
øDouble grouser
1-30
10) BUCKET
Capacity Tooth Width
Item
SAE heaped CECE heaped quantity Without side cutter With side cutter
Standard 1.44 m3 (1.88 yd3) 1.25 m3 (1.63 yd3) 5 1380 mm (54.3") 1500 mm (59.1")
0.9 m3 (1.18 yd3)
0.8 m3 (1.05 yd3) 3 950 mm (37.4") 1070 mm (42.1")
1.14 m3 (1.49 yd3) 1.0 m3 (1.31 yd3) 4 1110 mm (43.7") 1230 mm (48.4")
R330LC-9S 1.74 m3 (2.28 yd3) 1.5 m3 (1.96 yd3) 5 1620 mm (63.8") 1740 mm (68.5")
R330NLC-9S
H/WALKER Option 2.10 m3 (2.75 yd3) 1.8 m3 (2.35 yd3) 5 1910 mm (75.2") 2030 mm (79.9")
ľ1.44 m3 (1.88 yd3) 1.25 m3 (1.63 yd3) 5 1470 mm (57.9") -
◎1.44 m3 (1.88 yd3) 1.25 m3 (1.63 yd3) 5 1470 mm (57.9") -
◎1.73 m3 (2.26 yd3) 1.5 m3 (1.96 yd3) 5 1710 mm (67.3") -
ľ: Heavy duty bucket
◎: Rock-Heavy duty bucket
1-31
9. RECOMMENDED OILS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperatureĦC(ĦF)
Capacity
Service point Kind of fluid -20 -10 0 10 20 30 40
˶ (U.S. gal)
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine oil pan Engine oil 25.5 (6.7)
SAE 10W-30
SAE 15W-40
Swing drive 11.0 (2.9)

Gear oil SAE 85W-140
8.0Ý2
Final drive
(2.1Ý2)
ISO VG 32
Tank:
190 (50)
Hydraulic tank Hydraulic oil ISO VG 46
System:
330 (87)
ISO VG 68
ASTM D975 NO.1

Fuel tank Diesel fuel 500 (132)
ASTM D975 NO.2
NLGI NO.1
Fitting
Grease As required
(Grease nipple) NLGI NO.2
Mixture of
Radiator antifreeze
45 (12.0) Ethylene glycol base permanent type
(Reservoir tank) and water
50 : 50
SAE : Society of Automotive Engineers

API : American Petroleum Institute
ISO : International Organization for Standardization
NLGI : National Lubricating Grease Institute
ASTM : American Society of Testing and Material
1-32

Group 5 RCV Lever --------------------------------------------------------------------------------------------------------- 2-66
Group 6 RCV Pedal --------------------------------------------------------------------------------------------------------- 2-73
GROUP 1 PUMP DEVICE
1. STRUCTURE
The pump device consists of main pump, regulator and gear pump.
Pi1
A3
B3
Dr Psv
Pi2
a4
Qmin adjusting screw Qmax adjusting screw Qmin adjusting screw

Regulator Regulator
Pi1
Pi2
a4
Psv
Dr
B3
B1
a3
Dr3
a1 a2
Front pump Rear pump Gear pump
Port Port name Port size

A1 Psv a4 A2
A1, 2 Delivery port SAE6000psi 1"
B1 Suction port SAE2000psi 3"
a1 a2
Dr Drain port PF 3/4 - 23
Pi1, i2 Pilot port PF 1/4 - 15
Pi1 Pi2 Psv Servo assist port PF 1/4 - 15
a1, 2, 4 Gauge port PF 1/4 - 15
a3 Gauge port PF 1/4 - 14
a3 A3 Gear pump delivery port PF 1/2 - 19
B3 Dr3 A3
Dr B1 B3 Gear pump suction port PF 3/4 - 20.5
3309S2MP01
Dr3 Gear pump drain port PF 3/8 - 15
2-1
1) MAIN PUMP(1/2)
PUMP
The main pump consists of two piston pumps (front & rear) and valve block.
953 535 789 732 532 214 548 531 724 702 792 534 808 901 954 719 151 152 211 113
808 A
886
717
406
261
04
774
111
127
123
710
824
251 490 212 153 156 468 157 885 314 981 012 271 401
728 313 124 312 114 466 983
725
33092MP02A
04 Gear pump 271 Pump casing 719 O-ring

111 Drive shaft (F) 312 Valve block 724 O-ring
113 Drive shaft (R) 313 Valve plate (R) 725 O-ring
114 Gear 314 Valve plate (L) 728 O-ring
123 Roller bearing 401 Hexagon socket bolt 732 O-ring
124 Needle bearing 406 Hexagon socket bolt 774 Oil seal
127 Bearing spacer 466 VP plug 789 Back up ring
151 Piston 468 VP plug 792 Back up ring
152 Shoe 490 VP plug 808 Hexagon head nut
153 Set plate 531 Tilting pin 824 Snap ring
156 Bushing 532 Servo piston 885 Pin
157 Cylinder spring 534 Stopper (L) 886 Spring pin
211 Shoe plate 535 Stopper (S) 901 Eye bolt
212 Swash plate 548 Pin 953 Set screw
214 Bushing 702 O-ring 954 Set screw
251 Swash plate support 710 O-ring 981 Name plate
261 Seal cover (F) 717 O-ring 983 Pin
2-2
MAIN PUMP (2/2)
544
545
541
543
079
VIEW A
32092MP03
079 Proportional reducing valve 543 Stopper 1 545 Steel ball

541 Seat 544 Stopper 2
2-3
2) REGULATOR (1/2)
412 876 874 A

755
A 858
897 B P2
614
612 Pf
Pi
615
613
A 875
B 611
B
A Delivery port 1"

B Suction port 3"
Pi Pilot port PF 1/4-15
Pf Power shift pressure -
P2 Companion delivery pressure -
438
801
924
730 643 708 644 645 646 728
SECTION B-B
413 438
438
656
735 Pi
722
496 724 725 436
VIEW C 32092MP04
2-4
REGULATOR (2/2)
SECTION A-A
29092MP04A
412 Hexagon socket screw 630 Lock nut 733 O-ring

413 Hexagon socket screw 631 Sleeve, pf 734 O-ring
436 Hexagon socket screw 641 Pilot cover 735 O-ring
438 Hexagon socket screw 643 Pilot piston 753 O-ring
496 Plug 644 Spring seat (Q) 755 O-ring
601 Casing 645 Adjust stem (Q) 756 O-ring
611 Feed back lever 646 Pilot spring 763 O-ring
612 Lever (1) 651 Sleeve 801 Nut
613 Lever (2) 652 Spool 802 Nut
614 Fulcrum plug 653 Spring seat 814 Snap ring
615 Adjust plug 654 Return spring 836 Snap ring
621 Compensator piston 655 Set spring 858 Snap ring
622 Piston case 656 Block cover 874 Pin
623 Compensator rod 708 O-ring 875 Pin
624 Spring seat (C) 722 O-ring 876 Pin
625 Outer spring 724 O-ring 887 Pin
626 Inner spring 725 O-ring 897 Pin
627 Adjust stem (C) 728 O-ring 898 Pin
628 Adjust screw (C) 730 O-ring 924 Set screw
629 Cover (C) 732 O-ring
2-5
3) GEAR PUMP
700 354 351

887 433
B3
434 A3
311
850
312 a3 355
732
710 435 361 353 307 310 308 309 434 466, 725
29092MP05
307 Poppet 353 Drive gear 466 Plug

308 Seat 354 Driven gear 700 Ring
309 Ring 355 Filter 710 O-ring
310 Spring 361 Front case 725 O-ring
311 Screw 433 Flange socket 732 O-ring
312 Nut 434 Flange socket 850 Snap ring
351 Gear case 435 Flange socket 887 Pin
2-6
2. FUNCTION
1) MAIN PUMP
The pumps may classified roughly into the rotary group performing a rotary motion and working as
the major part of the whole pump function: the swash plate group that varies the delivery rates: and
the valve cover group that changes over oil suction and discharge.
(1) Rotary group

The rotary group consists of drive shaft
(F)(111), cylinder block (141), piston
shoes (151,152), set plate (153), spherical
bush (156), and cylinder spring (157).
The drive shaft is supported by bearing 124
313
(123,124) at its both ends. 141
157
The shoe is caulked to the piston to from 156
153
a spherical coupling. It has a pocket to 211
relieve thrust force generated by loading 151
pressure and the take hydraulic balance 111
152
so that it slides lightly over the shoe plate
(211). The sub group composed by a
piston and a shoe is pressed against the 123
shoe plate by the action of the cylinder
spring via a retainer and a spherical bush.
Similarly, the cylinder block is pressed
against valve plate (313) by the action of
the cylinder spring. 29092MP06
548
(2) Swash plate group
The swash plate group consists of swash 214 531
plate (212), shoe plate (211), swash plate
support (251), tilting bush (214), tilting pin 251 212
(531) and servo piston (532). 211
The swash plate is a cylindrical part
formed on the opposite side of the sliding 532
surface of the shoe and is supported by
the swash support.
29092MP07
If the servo piston moves to the right and
left as hydraulic force controlled by the
ɷ
regulator is admitted to hydraulic chamber
located on both sides of the servo piston,
the swash plate slides over the swash
ɷ
plate support via the spherical part of the
tilting pin to change the tilting angle (ɷ)
2-7
2-7
(3) Valve block group
The valve block group consists of valve
block (312), valve plate (313) and valve
plate pin (885).
The valve plate having two melon-shaped
ports is fixed to the valve block and feeds
and collects oil to and from the cylinder 312
block.
The oil changed over by the valve plate is 313
connected to an external pipeline by way
of the valve block.
885
Now, if the drive shaft is driven by a prime
mover (electric motor, engine, etc), it
rotates the cylinder block via a spline
linkage at the same time. If the swash 29092MP08
plate is tilted as in Fig (previous page) the

pistons arranged in the cylinder block
make a reciprocating motion with respect
to the cylinder block, while they revolve
with the cylinder block.
If you pay attention to a single piston, it
performs a motion away from the valve
plate (oil sucking process) within 180
degrees, and makes a motion towards the
valve plate (or oil discharging process) in
the rest of 180 degrees. When the swash
plate has a tilting angle of zero, the piston
makes no stroke and discharges no oil.
2-8
2) REGULATOR
Regulator consists of the negative flow control, total horse power control and power shift control
function.
(1) Negative flow control

By changing the pilot pressure Pi, the
pump tilting angle (delivery flow) is
regulated arbitrarily, as shown in the
figure.
This regulator is of the negative flow
Delivery flow, Q
control in which the delivery flow Q
decreases as the pilot pressure Pi rises.
With this mechanism, when the pilot
pressure corresponding to the flow
required for the work is commanded, the
pump discharges the required flow only,
and so it does not consume the power Pilot pressure, Pi
uselessly.
2-9
Η Flow reducing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
A
Pi(from MCV)
875
611
Small diameter
Large diameter Servo piston D 548 chamber
chamber
531
29092MP09A
As the pilot pressure Pi rises, the pilot piston (643) moves to the right to a position where the
force of the pilot spring (646) balances with the hydraulic force.
The groove (A) in the pilot piston is fitted with the pin (875) that is fixed to lever 2 (613).
Therefore, when the pilot piston moves, lever 2 rotates around the fulcrum of point B [Fixed by
the fulcrum plug (614) and pin (875)]. Since the large hole section (C) of lever 2 contains a
protruding pin (897) fixed to the feedback lever (611), the pin (897) moves to the right as lever 2
rotates. Since the opposing-flat section (D) of the feedback lever is fitted with the pin (548) fixed
by the tilting pin (531) that swings the swash plate, the feedback lever rotates around the fulcrum
of point D, as the pin (897) moves.
Since the feedback lever is connected with the spool (652) via the pin (874), the spool moves to
the right.
The movement of the spool causes the delivery pressure P1 to connect to port CL through the
spool and to be admitted to the large diameter section of the servo piston. The delivery
pressure P1 that is constantly admitted to the small diameter section of the servo piston moves
the servo piston to the right due to the area difference, resulting in decrease of the tilting angle.
When the servo piston moves to the right, point D also moves to the right. The spool is fitted
with the return spring (654) and is tensioned to the left at all times, and so the pin (897) is
pressed against the large hole section (C) of lever 2.
Therefore, as point D moves, the feedback lever rotates around the fulcrum of point C, and the
spool is shifted to the left. This causes the opening between the sleeve (651) and spool (652) to
close slowly, and the servo piston comes to a complete stop when it closes completely.
2-10
Θ Flow increasing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
Pi
875
611
Small diameter
Large diameter Servo piston D 548 chamber
chamber
531
29092MP10
As the pilot pressure Pi decreases, the pilot piston (643) moves to the left by the action of the
pilot spring (646) and causes lever 2 (613) to rotate around the fulcrum of point B. Since the pin
(897) is pressed against the large hole section (C) of lever 2 by the action of the return spring
(654) via the spool (652), pin (874), and feedback lever (611), the feedback lever rotates around
the fulcrum of point D as lever 2 rotates, and shifts the spool to the left. Port CL opens a way to
the tank port as the spool moves. This deprives the large diameter section of the servo piston of
pressure, and shifts the servo piston to the left by the discharge pressure P1 in the small
diameter section, resulting in an increase in the flow rate.
As the servo piston moves, point D also moves to the left, the feedback lever rotates around the
fulcrum of point C, and the spool moves to the right till the opening between the spool and sleeve
is closed.
2-11
Ι Adjustment of flow control characteristic
The flow control characteristic can be
adjusted with the adjusting screw.
Adjust it by loosening the hexagon nut 801
(801) and by tightening (or loosening) 924
the hexagonal socket head screw (924).
Tightening the screw shifts the control
chart to the right as shown in the figure.
ö Adjusting values are shown in table.
Adjustment of flow control
characteristic 2-12
Speed
Tightening Flow control Flow
amount of starting change
adjusting pressure amount
screw change
Delivery flow, Q
(924) amount
(min -1) (Turn) (kgf/cm2) (˶/min)
1750 +1/4 +1.5 +22.1
Pilot pressure, Pi
2-12
(2) Total horsepower control
The regulator decreases the pump tilting
angle (delivery flow) automatically to limit
the input torque within a certain value with
Delivery flow, Q
a rise in the delivery pressure P1 of the
self pump and the delivery pressure P2 of
the companion pump.
(The input horsepower is constant when
the speed is constant.)
Since the regulator is of the simultaneous
Delivery pressure, (P1+P2)
total horsepower type that operates by the
sum of load pressures of the two pumps
in the tandem double-pump system, the
prime mover is automatically prevented
from being overloaded, irrespective of the
load condition of the two pumps, when
horsepower control is under way.
Since this regulator is of the simultaneous
total horsepower type, it controls the tilting
angles (displacement volumes) of the two
pumps to the same value as represented
by the following equation :
Tin = P1Ýq / 2 ʆ + P2Ýq / 2 ʆ
= (P1+P2)Ýq / 2 ʆ
The horsepower control function is the
same as the flow control function and is
summarized in the following. (for detailed
behaviors of respective parts, refer to the
section of flow control).
2-13
Η Overload preventive function
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
F
P2 P1
875
611
Large diameter Servo piston Small diameter

chamber D chamber
29092MP11
When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it
acts on the stepped part of the compensating piston (621). It presses the compensating rod
(623) to the right till the force of the outer spring (625) and inner spring (626) balances with the
hydraulic force. The movement of the compensating rod is transmitted to lever 1 (612) via pin
(875).
Lever 1 rotates around the pin (875) (E) fixed to the casing (601).
Since the large hole section (F) of lever 1 contains a protruding pin (897) fixed to the feedback
lever (611), the feedback lever rotates around the fulcrum of point D as lever 1 rotates, and then
the spool(652) is shifted to the right. As the spool moves, the delivery pressure P1 is admitted to
the large diameter section of the servo piston via port CL, causes the servo piston move to the
right, reduces the pump delivery, flow rate, and prevents the prime mover from being overloaded.
The movement of the servo piston is transmitted to the feedback lever via point D. Then the
feedback lever rotates around the fulcrum of point F and the spool is shifted to the left. The
spool moves till the opening between the spool (652) and sleeve (651) is closed.
2-14
Θ Flow reset function
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
F
P2 P1
875
611
Large diameter Small diameter

chamber Servo piston D chamber
29092MP12
As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases,
the compensating rod (623) is pushed back by the action of the springs (625 & 626) to rotate
lever 1 (612) around point E. Rotating of lever 1 causes the feedback lever (611) to rotate
around the fulcrum of point D and then the spool (652) to move to the left. As a result, port CL
opens a way to the tank port.
This causes the servo piston to move to the left and the pump's delivery rate to increase.
The movement of the servo piston is transmitted to the spool by the action of the feedback
mechanism to move it till the opening between the spool and sleeve is closed.
2-15
Ι Low tilting angle (low flow) command preferential function
As mentioned above, flow control and horsepower control tilting angle commands are
transmitted to the feedback lever and spool via the large-hole sections (C & F) of levers 1 and 2.
However, since sections C and F have the pins (͚4) protruding from the large hole (͚8), only
the lever lessening the tilting angle contacts the pin (897) ; the hole (͚8) in the lever of a larger
tilting angle command is freed without contacting the pin (897). Such a mechanical selection
method permits preference of the lower tilting angle command of the flow control and
horsepower control.
Κ Adjustment of input horsepower
Since the regulator is of total cumulative horsepower type, adjust the adjusting screws of both
the front and rear pumps, when changing the horsepower set values. The pressure change
values by adjustment are based on two pumps pressurized at the same time, and the values will
be doubled when only one pump is loaded.
a. Adjustment of outer spring

Adjust it by loosening the hexagon nut
625 626 630 628
(630) and by tightening (or loosening)
the adjusting screw C (628). Tightening
the screw shifts the control chart to the 802
right and increases the input horsepower

as shown in the figure. Since turning
the adjusting screw C by N turns
changes the setting of the inner spring
(626), return the adjusting screw QI
627
(627) by NÝA turns at first. (A=1.59)
ö Adjusting values are shown in table.
Adjustment of outer spring 8007A2MP03
Speed
Tightening Compensating Input
amount of control torque
adjusting starting change
Delivery flow, Q
screw (C) pressure amount

(628) change
amount
(min -1) (Turn) (kgf/cm2) (kgfÂm)
1750 +1/4 +20.0 +8.3
2-16
b. Adjustment of inner spring
(802) and by tightening (or loosening) 626
802
the adjusting screw QI (627).
Tightening the screw increases the flow
and then the input horsepower as
shown in the figure.
ö Adjusting valves are shown in table.
627
Adjustment of inner spring
Speed
Tightening Flow change Input
amount of amount torque 8007A2MP04
adjusting (rpm) change
screw (QI) amount
(627)
Delivery flow, Q
(min -1) (Turn) (˶/min) (kgfÂm)
1750 +1/4 +15.9 +8.5
2-17
(3) Power shift control
621 651 652 623 612 625 626
P1 CL
B(E)
897
898 F
Pf
P2 P1
611
Large diameter Small diameter

chamber Servo piston D chamber
29092MP13
The set horsepower valve is shifted by varying

the command current level of the proportional
pressure reducing valve attached to the pump.
Delivery flow, Q
Only one proportional pressure reducing valve is

provided. Pf=
MIN
However, the secondary pressure Pf (power shift .
Pf=
pressure) is admitted to the horsepower control M AX
.
section of each pump regulator through the
pump's internal path to shift it to the same set
horsepower level. Delivery pressure, (P1+P2)
This function permits arbitrary setting of the
pump output power, thereby providing the optimum power level according to the operating
condition.
The power shift pressure Pf controls the set horsepower of the pump to a desired level, as shown
in the figure.
As the power shift pressure Pf rises, the compensating rod (623) moves to the right via the pin
(898) and compensating piston (621).
This decreases the pump tilting angle and then the set horsepower in the same way as explained
in the overload preventive function of the horsepower control. On the contrary, the set
horsepower rises as the power shift pressure Pf falls.
2-18
(4) Adjustment of maximum and minimum flows
808
Η Adjustment of maximum flow
Adjust it by loosening the hexagon nut 954
the set screw (954).
The maximum flow only is adjusted
without changing other control
characteristics. 2-19(1)
Adjustment of max flow

Speed
Delivery flow, Q
Tightening Flow change
amount of amount
adjusting screw
(954)
(min -1) (Turn) (˶/min)
1750 +1/4 -6.7 Delivery pressure, Pi
Θ Adjustment of minimum flow

808
the hexagonal socket head set screw
(953). Similarly to the adjustment of the 953
maximum flow, other characteristics are
not changed.
However, remember that, if tightened too
much, the required horsepower during 2-19(2)
the maximum delivery pressure (or

during relieving) may increase.
Adjustment of min flow

Delivery flow, Q
Speed
Tightening Flow change
amount of amount
adjusting screw
(953)
(min -1) (Turn) (˶/min)

Delivery pressure, Pi
1750 +1/4 +6.7
2-19
GROUP 2 MAIN CONTROL VALVE
1. STRUCTURE Mark Port name Port size Tightening torque

20~25 kgfÂm
R2 Make up port for swing PF 1
(115~180 lbfÂft)
XAtr Travel right (reverse) pilot port
XBtr Travel right (forward) pilot port
(XAo) Optional pilot port
(XBo) Optional pilot port
(XBp2)
XBa2 XAk Bucket in pilot port
XBtr (PTa) XBk Bucket out pilot port
Dr3 XAb1 Boom up pilot port
CP1
TRAVEL XBb1 Boom down pilot port
d1 d2 d3 RIGHT XAa2 Arm out confluence pilot port 7~8 kgfÂm
XBtr Btr Atr XAtr PF 3/8
XBa2 Arm in confluence pilot port (50.6~57.8 lbfÂft)
P1
LCs SWING
XAtL Travel left (reverse) pilot port
XAs Bs As XBs XBtL Travel left (forward) pilot port
SWING
(P3) PRIORITY XAs Swing left pilot port
P2 CCb BOOM 2 CCo (P5) PnA2 Dr7 XBs Swing right pilot port
Psp XAb2 Dr6 Pns (P4) XAa1 Arm out pilot port
Xb2 Dr1
XBa1 Arm in pilot port
R1 (XBo)
(XAo) Bo Ao OPTION
(PH) Pilot pressure port
LCo
(Pd) CCk Dr1 Drain port
Pis ARM 1
XAa1 Ba Dr3 XBa1 Px Pressure port for attachment
(Head)
LCa
Py Pressure port for travel
N2 Pc2
BYPASS XBp1
Pz Main relief pilot pressure port
(XBp2) BYPASS
CUT P1 Pc1
N1 CUT P2 PG Pilot pressure port
XAa2
XBk
Dr2 Drain port
(Pd)
XAtr Dr3 Drain port
PCk Dr6 Drain port
VIEW A
XBp1
VIEW B Dr7 Drain port
Pns Swing logic valve pilot port
PaL Lock valve pilot port (arm rod side)
PbL Lock valve pilot port (boom head side) 3.5~3.9 kgfÂm
XAb2 Boom up confluence pilot port PF 1/4 (25.3~28.2 lbfÂft)
(P0) PG Psp Swing priority pilot port
MR
Px
(PTa) XBtr XBp1 Bypass cut spool pilot port (P1 side)
TRAVEL Pz
STRAIGHT (PTa) (XBp2) Bypass cut spool pilot port (P2 side)
XAtr
CMR1 CMR2 (Pd) Breaker high pressure pilot lamp
Py
TRAVEL AtL
C2 XBtL XAs Dr2 Pc1 Posi-nega pressure port (P1 side)
LEFT XAtL
XBs XAtL CRb
BtL XBtL Pc2 Posi-nega pressure port (P2 side)
LCb Psp
PCk Bucket in stroke limiter pilot port
Dr6 PbL BbR
Pns BOOM 1 Pns Dr6 Pis Arm regeneration cut pilot port
XBb1 Bb XAb1 XAb1
A XAb2 XBb1 Ab (Rod) N1 Arm1 Nega-con pressure port

BoR
AbR BUCKET
(Head) LCk BkR (XAo) N2 Boom1 Nega-con pressure port
(Pd) PCk
XAk Bk PCk PnA2 Arm2 logic valve pilot port
XAk AkR Ak
(XBo) (Rod)
AoR (Head) LCAP2
XBk
AR ARM 2 CRa XBk
XAa1 BaR Atr Travel motor right side (reverse) port
XAa2
Dr3
XBa2
PaL
R2 XAa2 Btr Travel motor right side (forward) port
XBa1 XBa2
LCAT2 (Ao) Optional port
NR1
PH PnA2 Dr7 Dr7 PnA2 (Bo) Optional port
Aa
NR2
AaR
(Rod)
Ak Bucket cylinder head side port
(XBp2) XBp1
Bk Bucket cylinder rod side port
Ab Boom cylinder head side port
5~6.6 kgfÂm
Bb Boom cylinder rod side port
M10 (36.1~47.7 lbfÂft)
AtL Travel motor left side (reverse) port
B BtL Travel motor left side (forward) port
As Swing motor left port
Bs Swing motor right port
Aa Arm cylinder rod side port
Ba Arm cylinder head side port
P1 Pump port (P1 side)
P2 Pump port (P2 side)
8.5~11.2 kgfÂm
32092MC01 R1 Return port M12
(61.5~81.1 lbfÂft)
2-20
N
101 159 541 542 543 166
273x10
B A 101 Casing A (P2 housing) 308 Straight travel spool sub assy
550 153
102 Casing B (P1 housing) 309 Spool (option)
(Po) 151 Plug 310 Bypass cut spool
(PTa)
152 Plug 311 Swing priority spool
273x12 561 153 Plug 313 Bypass cut spool
N XAtr MR 154 Plug 320 Spring
C C 155 Plug 321 Spring
XAtL XBtl
156 Orifice 322 Spring
252 158 Plug 323 Spring
XBs XAtL
D D 159 Plug 326 Spring
XBb1 XAb1 Dr6 Pns
161 O-ring 327 Spring
977 XBb1
162 O-ring 329 Spring
XAb2
E 978x2 E 163 O-ring 331 Spring seat
AbR
XAk PCk
(Pd)
164 O-ring 332 Spring seat
165 O-ring 333 Bolt-spacer
(XBo) XAk AkR
XBk F AoR F 166 O-ring 335 Stopper
XBa2 XAa2 AR 167 O-ring 336 Bolt-spacer
168 O-ring 337 Stopper
Dr3 XBa1 XBa2 201 Cover 339 Stopper
G G
PnA2 Dr7 202 Cover 370 Spring
252 203 Cover 371 Spring
H PH PCV2 O AaR
O AaR 204 Cover 372 Spring
(XBp2) H
205 Cover 373 Spring
A 602 206 Cover 511 Poppet
514 521 561 551 551 561 521 514 151 168 151 168 151
B XBa2 208 Cover 512 Poppet
SECTION A-A 168 209 Flange 513 Poppet
(XBp2) Pp 210 Plate 514 Poppet
153 561 PG 156
P1 (P5) R1 102 Pss 211 Piston 521 Spring
156 Dr3 250 Logic control valve assy 522 Spring
975 975
251 Logic control valve assy 523 Spring
SECTION N-N
SECTION O-O 252 Lock valve selector sub assy 541 Steel ball
254 Logic poppet assy 542 Spring seat
XBtr XAtr
256 Logic poppet assy 543 Spring
975 257 Arm regeneration cut sub assy 550 Plug
258 Plug 551 Plug
XAs XBs 259 Plug 552 Plug
274x4 260 Plug 553 Plug
975
261 O-ring 561 O-ring
(P5)
Pns 262 O-ring 562 O-ring
Psp XAb2
PnA2 Dr7
Dr6 264 O-ring 601 Main relief valve assy
P P 273 Socket bolt 602 Port relief valve assy
975
153 561 274 Socket bolt 603 Port relief valve assy
XAo XBo
210 (P5)
301 Travel spool 604 Port relief valve assy
975 975 302 Arm 1 spool sub assy 610 Nega-con relief valve
303 Boom 1 spool sub assy 971 Bolt
XAa1 XBa1
SECTION P-P 304 Bucket spool 975 Bolt
975 305 Swing spool 977 Name plate
306 Arm 2 spool 978 Pin
XBp1 XBp2 XAa2 307 Boom 2 spool
975 XBk
975 273x12 PCk 273x10
XBp1
165 165 167 155 165
SECTION B-B 32092MC02
2-21
TRAVEL RIGHT TRAVEL STRAIGHT 154 SWING TRAVEL LEFT 201 BOOM2 BOOM1
164 202 201
201 201 336
201 336 336
336 336 336 332
335 332 332
332 332 332
323 323 339 335
335 335
335 322 327
323 322 323 321
322 601 322 332 326
261 320
332 332
332 261 332 301 602
261 308 261 261 L
L 332
305 161 261
301
161 511 158
165 521
163 521
512 163
511 522 551 552
254 511 561
521 553 561
521 165 513
551 307 511
561 562 551 163
165 562 521
561
163 551 551
163 250
561 561
163 553 311
522 303
512 161
165 163 602
159
264 261 264
264
204 204 332
264 264 208
164 320 Q Q
259 154 204 163 204 329
164 158
SECTION C-C SECTION D-D 339
152 201 332
201 OPTION BUCKET 201
162 336 201 336
336 ARM2 260
336 332 336 202 SWING PRIORITY
332
332 335 ARM1 332
335 335 168
335 SECTION E-E
321 321 323
321
320 322
320 320
332 332
261 602 257 SECTION L-L SECTION Q-Q
261
603 332 332
163 261 L L 306
261
209 304 158
971x4 163
165 165 513
309 523 610 162 152 158 154 164 164 154 158 152 162 162 152
162
163 152 561
164
163 165 552
511 251 154
511 610
521 521 302
511
551 551 BYPASS CUT 1 BYPASS CUT 2
521
561
561 551 256
163 561 551
165 163 561
971x4 521
209 511 203
602 333 331 371 331 262 313 165 165 310 163 331 371 331 203
163
264 165
264
206 370 337 262 337 370 333
604 163
211 SECTION H-H
204 264 264
164 561
258 602
154 204
SECTION F-F 205 SECTION G-G 32092MC03
2-22
2. HYDRAULIC CIRCUIT
(P4) (P5)
XBp2
NR1 NR2
Pi2 PS
(Pump) N2
Pi1
(Pump) PS N1 R2
XBp1
CCk PaL
Hya
CCo
PaL Aa
Pi1(Arm safety) BaR
XBa2 Ba
AaR
ARM 1 XBa1 XAa2 ARM 2
XAa1 XBa2
XAa2 LCAP2 LCAT2
LCa
Dr3 Dr7
PnA2
AR BoR
Pis
AkR
Pd Ak
Bo Bk
Ao BkR
AoR XBp1
OPTION XAo XAk BUCKET
LCo XBk
XBo
PCk
LCk
PbL
HVb
CCb
Ab
BbR PnA2
PCk
AbR XAb1
Bb XAb2
BOOM 2 XAb2
PbL
BOOM 1
LCb Pi1(Boom safety)
Psp XBb1
C2
Pns Dr1
Bs AtL
As BtL
SWING XAs XAtL TRAVEL(LH)
XBs XBtL
LCs
Dr6 PS
Dr2 Py
Btr CPG
Atr CP1 PS STRAIGHT
Px TRAVEL
TRAVEL(RH) XAtr
SH
XBtr CMR2
Pz (Swing motor)
CMR1 MR
P1 R1 Po P2 PG
32092MC04
2-23
3. FUNCTION
1) CONTROL IN NEUTRAL POSITION
Main circuit
Main
When all spools are in the neutral positions, the pressurized oil discharged from the hydraulic pump
(A1) passes through Port P1, the main path (1), the bypass circuit (2) passing the spools for travel
right (301), swing (305), boom confluence (boom 2; 307), option (309) and arm 1 (302), and the
arm 1 side negative control relief valve (610), and returns to the hydraulic oil tank through the tank
port (R1).
The negative control signal pressure of the arm 1 side negative control relief valve (610) is led from
Port N1 to the regulator on the hydraulic pump (A1) side, and controls the pump discharge flow rate
to its minimum value.
The oil discharged from the hydraulic pump (A2) passes through Port P2, the main path (3), the
bypass circuit (2) passing the spools for travel left (301), boom 1 (303), bucket (304) and arm 2
(306), and the boom1 side negative control relief valve (610), and returns to the hydraulic oil tank
through the tank port (R1).
The negative control signal pressure of the boom 1 side negative control relief valve (610) is led
from Port N2 to the regulator on the hydraulic pump (A2) side, and controls the pump discharge
flow rate to its minimum value.
When any of nine main spools is changed over, the bypass circuit (2) is cut off and the hydraulic oil
at Port N1 or N2 in the negative control circuit is shut off.
2-24
P2
3
2 P2 Housing
(Casing 1)
TRAVEL
STRAIGHT
301
XAtL XBtL
TRAVEL(LH) 303
XBb1 XAb1
BOOM 1
304
XAk PCk
BUCKET
XBk
XBa2 XAa2
ARM 2
306
CCo CCk
SPOOL SECTION(P2) 32092MC05
1 2 307
P1 R1
P1 Housing
301 (Casing 2)
XBtr XAtr
TRAVEL(RH)
305
XAs XBs
SWING
Psp XAb2
BOOM 2
SWING
PRIORITY
XAo XBo
OPTION
309
XAa1 XBa1
ARM 1
302
XBp1 XBp2
BYPASS
BYPASS CUT P2
CUT P1
P4
SPOOL SECTION(P1)
32092MC06
2-25
2) EACH SPOOL OPERATION
(1) Travel control
301
XBtr
XAtr
Atr Btr
21092MC21
Pilot circuit
Since any of the travel spools (301) on the left or right transfers and shuts off the side-bypass path,
the pressure at Port Py increases.
Main circuit
When Pilot Port XBtr of the travel right spool (301) is pressurized, the bypass circuit (2) in the arm 1
side is shut off and the working fluid discharged from the hydraulic pump (A1) through Port Btr and
flows to the travel right motor.
When Pilot Port XBtL of the travel left spool (301) is pressurized, the bypass circuit (2) in the
boom 1 side is shut off and the working fluid discharged from the hydraulic pump (A2), similarly to
that from the hydraulic pump (A1), through Port BtL and flows to the travel left motor.
On the other hand, the return oil from the right and left travel motor passes flows from Port Atr (AtL)
to the travel right (left) spools (301) and returns to the hydraulic oil tank through the tank port (R1).
In the case of the opposite operation (when the pilot pressure is applied to Ports XAtr and XAtL of
the control valve), the operation is similar.
2-26
(2) Arm control
Η Arm out operation
256 511 306

Aa
XAa2
XBa2
XAa1
XBa1
Ba
302 511
21092MC13
Pilot circuit
Since the arm 2 spool (306) transfers and shuts off the side-bypass path, the pressure at Port Px
increases.
Main circuit
During the arm out operation, the pilot pressure enters through Ports XAa1 and XAa2. When the
pressure enters through Port XAa1 and XAa2, the spools transfer in the left direction. The hydraulic
oil entering through Port P1 passes through the main path (1) and flows to the bypass circuit (2),
but the bypass circuit is shut off due to transfer of the arm 1 spool (302).
Therefore, the hydraulic oil from the parallel circuit pushes open the check valve (511) and flows
through the U-shaped path to the arm 1 spool (302). Then, it flows around the periphery of the arm
1 spool (302) and the arm 2 spool (306) to Port Aa, and is supplied to the arm cylinder rod side.
On the other hand, the hydraulic oil entering through Port P2 passes in the main path (3), and flows
into the bypass circuit (2), and the bypass circuit is shut off due to transfer of the arm 2 spool (306).
The hydraulic oil from the parallel circuit pushes open the logic poppet (256) and the hydraulic oil
from the bypass circuit (2) pushes open the check valve (511) and flows through the U-shaped path
to the arm 2 spool (306). Then, it flows around the periphery of the arm 2 spool (306) in the inside
path and joins into Port Aa.
Besides, the return oil from the arm cylinder head side passes through Port Ba, flows into tank line
in arm 1 side and in arm 2 side, and returns to the hydraulic oil tank through the tank port (R1).
2-27
Θ Arm in operation
ÂDuring
During light load only
Arm self weight
P2
Aa
306
XBa2
XAa2
302-317
XBa1
XAa1
Ba (b)
(a) 302 P1
21092MC14
Pilot circuit
Since the arm 2 spool (306) transfers and shuts off the side-bypass path, the pressure at Port Px
increases. Then, the pressure enters also through Port PaL and the release signal is sent to the
lock valve (252).
Main circuit
During the arm in operation, the pilot pressure enters through Ports XBa1 and XBa2. When the
pressure enters through Port XBa1 and Port XBa2, the spools transfer in the right direction Fig.
MC14. The hydraulic oil entering through Port P1 passes through the main path (1) and flows to
the bypass circuit (2), but the bypass circuit is shut off due to transfer of the arm 1 spool (302).
Therefore, the hydraulic oil from the parallel circuit pushes open the check valve (511) and flows
through the U-shaped path to the arm 1 spool (302). Then, it flows around the periphery of the
arm 1 spool (302) to Port Ba, and is supplied to the arm cylinder head side.
On the other hand, the hydraulic oil entering through Port P2 passes in the main path (3), and flows
into the bypass circuit (2), and the bypass circuit is shut off due to transfer of the arm 2 spool (306).
The hydraulic oil from the parallel circuit pushes open the logic poppet (256) and the hydraulic oil
from the bypass circuit (2) pushes open the check valve (511) and flows through the U-shaped
path to the arm 2 spool (306). Then, it flows around the periphery of the arm 2 spool (306) and
the arm 1 spool (302) in the inside path and joins into Port Ba.
Besides, the return oil from the arm cylinder rod side is pressurized by self-weight of the arms
and so on, and returns to Port Aa. The pressurized oil returning to Port Aa enters into the spool
through the periphery hole (a) of the arm 1 spool (302). During a light load only, it pushes open the
check valve (302-317) and joins into Port Ba from the spool hole (b). The rest of oil returns to the
hydraulic oil tank through the tank port (R1). This is called the arm regeneration function.
2-28
ÂThe
The pressure in the arm cylinder head side increases
Aa
XBa 2
302-317
XBa1
(c)
Ba
257-211 Pis (a)
21092MC15
When the pressure in the arm cylinder head side and the U-shaped path increases, the arm
regeneration cut spool (257-211) is transferred in the left direction, and at the same time the
check valve (302-317) is closed by its backpressure. This shuts off the arm regeneration
function, and the return oil from the arm cylinder rod side enters from Port Aa through the
periphery hole (a) of the arm 1 spool (302) into the spool, flows to the arm regeneration cut valve
(257) through the periphery hole (c) of the arm 1 spool (302), and returns through the tank port
(R1) to the hydraulic oil tank.
When the Pilot Port Pis of the arm regeneration cut spool (257-211) is pressurized, a part of the
return oil from the arm cylinder rod side flows to the arm regeneration cut valve (257) and returns
through the tank port (R1) to the hydraulic oil tank. (Variable arm regeneration)
2-29
Ι Arm 2 logic control valve operation
251-102
(b)
(a)
256-102
(c) (d) (e)
256-101
306
XAa 2
21092MC16
During both the arm in operation and the boom up operation, the pilot pressure enters through
Ports XBa1, XBa2, XAb1, XAb2, PaL and PnA2. The pressure PnA2 transfers the spool (251-102)
in the arm 2 logic control valve to the top direction, and the path from (a) to (b) is closed. Hereby,
the pressurized oil pushes open the poppet (256-102), passes in the path (c) and (d), enters into
the chamber (e), and the poppet (256-101) is pushed to the casing seat. Therefore, the most of
pressurized oil entering through Port P2 flows to the boom 1 spool (303) than the arm 2 spool (306)
to make the boom hoisting operation most preferential.
On the other hand, in the independent arm in operation, the pilot pressure does not enter through
Ports PnA2, and the path from (a) to (b) is not closed, and the hydraulic oil of the chamber (e) flows
to the path (a) and (b). The pressurized oil entering through Port P2 pushes open the poppet (256-
101) and flows to the arm 2 spool (306).
2-30
(3) Boom control
Η Boom up operation
511 303
Ab
Bb
XAb1
XAb 2
307
511
21092MC11
Pilot circuit
Since the boom 1 spool (303) transfers and shuts off the side-bypass path, the pressure at Port Px
increases.
Main circuit
During the boom up operation, the pilot pressure enters through Port XAb1 and moves the boom 1
spool (303) in the left direction. The pressurized oil entering through Port P2 passes through the
main path (3) and flows to the bypass circuit (2), but the bypass circuit (2) is shut off due to transfer
of the boom 1 spool (303). Therefore, the pressurized oil flows into the parallel circuit, pushes open
the check valve (511), and flows through the U-shaped path to the boom 1 spool (303). Then, it
flows around the periphery of the boom 1 spool (303) to Port Ab, and is supplied to the boom
cylinder head side.
At the same time, the pilot pressure enters also through Port XAb2 to transfer the boom 2 spool
(307) in the right direction. Though the pressurized oil enters into Port P1, the bypass circuit (2) is
shut off due to transfer of the boom 2 spool (307). Therefore, the hydraulic oil flows in the parallel
circuit and flows through the U-shaped path to the boom 2 spool (307). Then, the hydraulic oil
passes through the periphery of the boom 2 spool (307), pushes open the check valve (511), joins
into Port Ab in the inside path, and is supplied to the boom cylinder head side. (Boom confluent
flow)
On the other hand, the return oil from the boom cylinder rod side enters through Port Bb and
returns to the hydraulic oil tank through the tank port (R1).
2-31
Θ Boom down operation
511
Ab
Bb
XBb1
(c) (b) (a) 303 303-317
21092MC12
Pilot circuit
Since the boom 1 spool (303) transfers and shuts off the side-bypass path, the pressure at Port Px
increases. Then, the pressure enters also through Port PbL and the release signal is sent to the
lock valve (252).
Main circuit
During the boom down operation, the pilot pressure enters through Port XBb1 and transfers the
boom 1 spool (303) in the right direction. The pressurized oil entering through Port P2 passes
through the main path (3) and flows to the bypass circuit (2), but the bypass circuit (2) is shut off
due to transfer of the boom 1 spool (303). Therefore, the pressurized oil flows into the parallel
circuit, pushes open the check valve (511), and flows through the U-shaped path to the boom 1
spool (303). Then, it flows around the periphery of the boom 1 spool (303) to Port Bb and is
supplied to the boom cylinder rod side.
On the other hand, the return oil from the boom cylinder head side passes to the holes (a) and the
notches (b) of the boom 1 spool (303).
Since this return oil has a sufficient pressure caused by the weight of the boom, it passes through
the path inside the spool, pushes the poppet (303-317) in the spool in the right direction, flows
around the outside of the spool. Then, it is supplied again to the boom cylinder rod side as
hydraulic oil to lower the boom. (Boom regeneration)
Besides, a part of the return oil from the boom cylinder flows from the hole (c) into the tank.
2-32
(4) Bucket control
Η Bucket in operation
Ak Bk
XAk PCk
304
21092MC17
Pilot circuit
Since the bucket spool (304) transfers and shuts off the side-bypass path, the pressure at Port Px
increases. Then, the pressure enters also through Port XBp1.
Main circuit
During the bucket in operation, the pilot pressure enters through Port XAk and transfers the bucket
spool (304) in the right direction. The pressurized oil entering through Port P2 passes through
the main path (3) and flows through the bypass circuit (2), but the bypass circuit (2) is shut off due
to transfer of the bucket spool (304). Therefore, the pressurized oil flows into the parallel circuit,
pushes open the check valve (511), and flows through the U-shaped path to the bucket spool (304).
Then, it flows through the periphery of the spool to Port Ak and is supplied to the bucket cylinder
head side.
On the other hand, the return oil from the bucket cylinder rod side enters through Port Bk, passes
around the periphery of the spool, and returns to the hydraulic oil tank through the tank port (R1).
During both the boom up operation and bucket in operation, the pilot pressure enters through
Port PCk and the bucket spool transfers in the half stroke not full stroke. Therefore, the most of
pressurized oil entering through Port P2 flows to the boom 1 spool (303) than the bucket spool
(304) to make the boom up operation most preferential.
2-33
Θ Bucket out operation
Pilot circuit
Since the bucket spool (304) transfers and shuts off the side-bypass path, the pressure at Port
Px increases.
Main circuit
During the bucket out operation, the pilot pressure enters through Port XBk and transfers the
bucket spool (304) in the left direction. The pressurized oil entering through Port P2 passes
through the main path (3) and flows through the bypass circuit (2), but the bypass circuit (2) is
shut off due to transfer of the bucket spool (304). Therefore, the pressurized oil flows into the
parallel circuit, pushes open the check valve (511), and flows through the U-shaped path to the
bucket spool (304). Then, it flows through the periphery of the spool to Port Bk and is supplied to
the bucket cylinder rod side.
On the other hand, the return oil from the bucket cylinder head side enters through Port Ak,
passes around the periphery of the spool, and returns to the hydraulic oil tank through the tank
port (R1).
Ak Bk
XBk
21092MC18
Ι Bucket in confluence
During the bucket in operation, the pilot pressure enters also through Port XBp1 and transfers
the bypass-cut spool (313). The pressurized oil entering through Port P1 passes through the
main path (1) and flows through the bypass circuit (2), but the bypass circuit (2) is shut off due
to transfer of the bypass-cut spool (313). Therefore, the pressurized oil pushes open the check
valve CCk (514), and flows through inside path and the U-shaped path to the bucket spool (304).
2-34
(5) Swing control
Η Swing operation
Pilot circuit
Since the swing spool (305) transfers and shuts off the side-bypass path, the pressure at Port Px
increases.
Main circuit
During the swing operation, the pilot pressure enters through Port XAs (or XBs) and transfers the
swing spool (305). The pressurized oil entering through Port P1 passes through the main path
(1) and flows through the bypass circuit (2), but the bypass circuit (2) is shut off due to transfer of
the swing spool (305). Therefore, the pressurized oil flows into the parallel circuit, pushes open
the check valve (511), and flows through the U-shaped path to the swing spool (305). Then, it
flows through the periphery of the spool to Port As (or Bs) and is supplied to the swing motor.
On the other hand, the return oil from the swing motor enters Port Bs (or As) and returns to the
hydraulic oil tank through the tank port (R1).
Θ Swing logic control valve operation

During both the swing operation and the boom up operation, the pilot pressure enters through
Ports XBs (or XAs), XAb1, XAb2 and Pns. The pressure Pns transfers the spool (250-102) in
swing logic control valve. Hereby, the pressurized oil pushes open the poppet (254-102), and the
poppet (254-101) is pushed to the casing seat. Therefore, the most of pressurized oil entering
through Port P1 flows to the boom 2 spool (307) than the swing spool (305) to make the boom
up operation most preferential.
On the other hand, in the independent swing operation, the pilot pressure does not enter through
Ports Pns. The pressurized oil entering through Port P1 pushes open the poppet (254-101) and
flows to the swing spool (304).
XBs XAs
305
As Bs
254-101 254-102
250-102
21092MC19
2-35
Ι Swing operation preference function
311
Psp
21092MC20
Pilot circuit
The pilot pressure enters through Port Psp to transfer the swing priority spool (311).
Main circuit
Due to transfer of the swing priority spool (311), the open area of the swing priority spool
decreases, and the most of the pressurized oil entering through Port P1 flows to the swing side to
make the swing operation most preferential.
2-36
(6) Travel straight operation
Simultaneous operating of both travel spools (301) and other spool.
A case where both travel spools (301) and swing spool (305) are changed over will be considered.
(The pilot Ports XAtL, XAtr and XAs are pressurized.)
308 P2 P1
PTa
301
21092MC22
Pilot circuit
Since the side bypass sections of both travel spools (301) close and the side bypass section of the
downstream-side swing closes, the pilot pressure from the port PG enters through the port PTa to
transfer the travel straight spool (308).
Main circuit
After changeover of the travel straight spool (308), the port P1 and both travel spools (301) are
connected preferentially and the port P2 and the parallel paths of swing, boom 2, option and
arm 1 / boom 1, bucket and arm 2 are connected preferentially. Therefore, the pressurized oil
entering through Port P1 passes through mainly ports AtL and Atr, and flows to both travel motors
separately.
On the other hand, the pressurized oil entering through Port P2 flows to Port As and is supplied to
the swing motor.
When the pressure of Port P1 is lower than the pressure of Port P2, the part of oil entering through
Port P2 flows into Port P1 side. Therefore, it prevents the rapid slowdown of the travel.
2-37
3) FUNCTION
UNCTION OF LOCK VALVE
The lock valve (252) is fitted between the arm cylinder rod side and the arm 2 spool (306). It
decreases the leakage by the pressure of the cylinder.
Another lock valve (252) is similarly fitted between the boom cylinder head side and the boom 1
spool (303). It decreases the leakage by the pressure of the cylinder.
(1) Neutral positions of spools
The following is the case of the boom 1 spool (303). (The case of the arm 2 spool (306) is in the
same way.)
During the boom 1 spool (303) is in the neutral position, the lock valve (252) is kept in the position
shown in figure. The spool (252-511) in the lock valve is pushed to the seat of the sleeve (252-
541) by the force of the spring (252-321).
In this position, the pressurized oil from the boom cylinder head side enters through the hole (a),
the periphery of the spool (252-511) in the lock valve and the hole (b), and it pushes the poppet
(513) to the casing seat, and the leakage is decreased.
252-321 252-511
252-541
(b)
513
(a)
21092MC35
2-38
(2) Boom down operation
During the boom down operation, the pilot pressure enters through Port PbL and XBb1. The pilot
pressure transfers the spool (252-511) in the lock valve assy in the top direction. By the transfer of
the spool (252-511), firstly the hole (a) is blocked and the pressurized oil from the boom cylinder
head side does not enter to the spring chamber (RH). Secondly, the oil in the spring chamber
(RH) enters through the hole (b) and flows to drain circuit. Therefore, the poppet (513) is lifted by
the pressure of the boom cylinder head side and the function of the lock valve (252) is released.
252-511
Dr (RH)
(b)
513
(a)
PbL
XBb
21092MC36
(3) Boom up operation

During the boom up operation, the pilot pressure enters through Port XAb1. The oil flowing from
the boom 1 spool pushes open the poppet (513) and flows to Port Ab.
2-39
5) CIRCUIT PRESSURE PROTECTION
The control valve has two kinds of relief valve to limit the pressure in a circuit.
(1) Main relief valve
The main relief valve is fitted in the casing A and functions as follows.
541 611 621
512 A Pz 103 614
21092MC25
Η The hydraulic oil is filled up in the inside space chamber (A) from the path (P) through a hole of the
seat (541) and a restriction of the plunger (512), and seats the plunger (512) against the seat (541)
securely.
Θ When the pressure in the path (P) becomes equal to the set load of the spring (621), the poppet
(611) opens to make the hydraulic oil flow through a hole of the plug (103), around the poppet
(611) and into the low pressure path (R).
Ι Opening of the poppet (611) causes the pressure in the chamber (A) to fall and the plunger (512)
to open. As the result the pressurized oil in the path (P) runs into the low pressure path (R) directly.
Κ When the pressurized oil higher than pressure 30 kgf/cm2 enters through the port Pz, it pushes the
piston (614) to change the relief set pressure of the spring (621) to the high pressure.
2-40
(2) Port relief valve
The port relief valve is fitted between the cylinder port and low-pressure path. In addition to the
relief valve, this serves also as an anti-cavitation check valve, and functions as follows:
Η Function as relief valve
a. The pressurized oil passes through Hole A of the piston (301), is filled up in Chamber B of the
inside space, and seat the plunger (511) against the seat (541) securely.
A B
R
301 511 541
A B
R
301 511 541
A B
R
301 511 541
21092MC26
2-41
b. When the pressure in the path (P) becomes equal to the set pressure of the spring (621 or
622), the pressurized oil pushes open the poppet (611), flows around it, and flows to the low
pressure path (R) through hole C.
R
611 621
R
611 621
P FL
R
611 622
21092MC27
2-42
c. Opening of the poppet (611) causes the pressure in Chamber B to fall and the plunger (511) to
open. As the result the pressurized oil in the path (P) runs into the low pressure path (R)
directly.
R
511 611
R
511 611
P PL
R
511 611 622 624 105
21092MC28
d. When the pressurized oil higher than pressure 25 kgf/cm2 enters through the port PL, it pushes
the piston (624) to change the relief set pressure of the spring (622) to the high pressure.
2-43
Θ Function as Anti-Cavitation Check Valve
When any negative pressure exists in the path (P), the oil is supplied through the path (R).
When the pressure at (R) becomes higher than that in the path (P), the seat (541) moves in the
right direction. Then, sufficient oil passes around the seat (541) from the path (R) to the path
(P) and prevents cavitation.
R
541
R
541
R
541
21092MC29
2-44
(3) Negative control relief valve
The negative control relief valve is fitted between tne downstream of the center bypass path and
low-pressure path, and functions as follows.
Η When the pressure in the path (P) falls
below the set level of the spring (321), the
511 321 512
poppet (511) is in the condition shown
R
in the figure. The pressure acting area
of the poppet (511) is reduced to (øB
P
A
-øA), as the area øB is cancelled by the
area øA of the damping rod (512).
32092MC07
Θ In this condition, the pressurized oil in the

path (P) runs out to the path (R) through
the orifice (c). R
(c)
32092MC08A
Ι When the pressure in the path (P) goes

over the set P pressure of the spring
511 321
(321), the poppet (511) opens. Then, the
R
pressurized oil in the path (P) passes
around the outside of the poppet (511)
P
and flows to the low-pressure path (R).
The relation between the flow rate Q and
pressure P of the hydraulic oil that flows
from the path (P) to the low-pressure 32092MC09A
path (R) is as shown in the diagram.
Pressure P
0 Flow rate Q
32092MC10
2-45
GROUP 3 SWING DEVICE
1. STRUCTURE
Swing device consists swing motor, swing reduction gear.
Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve.
R/G grease port Reduction gear Swing motor Drain valve assy
PA PB
A, B
Level gauge
C
SH Relief valve
PG Time delay valve Fill port(IP)
IP SH DB
SH
32092SM01
PG
DB Port Port name Port size
A, B Main port SAE 5000psi 3/4"
DB Drain port PF 1/2-19
C Make up port PF 1-24
PA, PB Gauge port PF 1/4-12
C
PA PB PG Brake release port PF 1/4-12
SH Brake pilot port PF 1/4-12
IP Grease inlet port PT 1/4
A B
2-46
1) SWING MOTOR
121 120 117 116 142 141 119 118 140 113 236 227 123 124 125 126 235
143
137
113
139
145 A
138
144 A
114
122 133
X
136 X
102 115
130 134
129
135
103
101
104 105 106 111 108 131 109 110 107 112 132 146 127
128
236 237
SECTION A - A SECTION X-X

32092SM02
101 Casing A1 118 Brake spring 135 Ring snap

102 Drive shaft 119 Brake piston 136 Dust plug
103 Shoe plate 120 Piston 137 Ring snap
104 Shoe 121 Spacer F 138 Name plate
105 Retainer 122 Front cover 139 Rivet screw
106 Spherical bush 123 RO plug 140 O-ring
107 Brake valve 124 Spring 141 O-ring
108 Cylinder block 125 Plunger K 142 O-ring
109 Friction plate 126 S/reaction less valve 143 Ring snap
110 Separation pate 127 Relief valve 144 Roller bearing
111 Push rod 128 VP plug 145 O-ring
112 Valve plate 129 Ring snap 146 Socket bolt
113 Spacer 130 Oil seal 227 Socket bolt
114 VP plug 131 Dust plug 235 Pin
115 Valve casing 132 Pin spring 236 Level gauge
116 Cylinder spring 133 Roller bearing 237 Air breather assy
117 Spacer R 134 Dust plug
2-47
2) REDUCTION GEAR
233 234
220 218 228 221 232 230 204 222 206 205 207 210 226 209 225
223
A
231
229
202
216
219 214 201 224 203 211 215 213 217 208 212
32092RG01
201 Casing 212 Sun gear 1 223 Socket bolt

202 Pinion shaft 213 Ring gear 224 Hex bolt
203 Preload plate 214 Cover 225 Needle bearing
204 Carrier 2 215 Thrust washer 226 Inner ring
205 Planet gear 2 216 Thrust plate 228 PT plug
206 Pin 217 Thrust washer 229 Snap ring
207 Bush 218 Oil seal 230 Magnet
208 Carrier 1 219 Socket bolt 231 Flat head screw
209 Planet gear 1 220 Spherical roller bearing 232 Connector
210 Thrust washer 221 Cylindrical roller bearing 233 Hose assembly
211 Sun gear 2 222 Spring pin 234 Drain valve assembly
2-48
2. FUNCTION
1) ROTARY PART
When high pressurized oil enters a cylinder through port (a), which is the inlet of valve plate (112),
hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the
piston (120) upon the retainer (105) which acts upon the shoe plate (103) via an hydrostatic
bearing. Force F1 perpendicular to shoe plate (103) and force F2 perpendicular to cylinder center.
Being transferred to the cylinder block (108) through piston, force F2 causes rotational moment at
surroundings of cylinder.
Since cylinder block has 9 equidistantly arrayed pistons, rotational torque is transmitted to cylinder
shaft in order by several pistons connected to the inlet port of high pressurized oil. When the
direction of oil flow is reversed, rotational direction of cylinder is also reversed. Output torque is
given by the equation.
pÝq F
T= , q=ZÂAÂPCDÂtanɾ, F1 = , F2=F tanɾ , S=PCDÝtanɾ
2ӕ COSɾ
Where p : Effective difference of pressure (kgf/cm2)

q : Displacement (cc/rev)
T : Output torque (kgfÂcm)
Z : Piston number (9EA)
A : Piston area (cm2)
ɾ : Tilting angle of swash plate (degree)
S : Piston stroke (cm)
Low High
pressure oil pressure oil
F1 F2
112
103 105 120 108

32092SM03
2-49
2) MAKE UP VALVE
In the system using this type of motor, there is no counter balance functioning valve and there
happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation
caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency.
A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure
feed pressure required when the hydraulic motor makes a pumping action. The boost pressure
acts on the hydraulic motor's feed port via the make up valve.
Pressurized oil into the port B, the motor rotate counterclockwise.
If the plunger of MCV moves neutral position, the oil in the motor is drain via left relief valve, the
drain oil run into motor via right make up valve, which prevent the cavitation of motor.
A B
29072SM09
2-50
3) RELIEF VALVE
3
1 Body
5
2 O-ring
4 3 Plug
15
4 O-ring
5 Back up ring
11
6 Plunger
14 7 Piston
7 8 Spring
13
9 Seat spring
9 10 Seat
12
2 11 Sleeve
12 Adjust plug
1 13 O-ring
14 Back up ring
8 15 Nut
10
29072SM03
(1) Construction of relief valve

The valve casing contains two cartridge type relief valves that stop the regular and reverse
rotations of the hydraulic motor. The relief valves relieve high pressure at start or at stop of swing
motion and can control the relief pressure in two steps, high and low, in order to insure smooth
operation.
(2) Function of relief valve

Figure illustrates how the pressure acting P P=pressure, T=time
on the relief valve is related to its rising PS
process. Here is given the function, 4
referring to the figure following page.
P1 3
T
1
29072SM05
2-51
Η Ports (P, R) at tank pressure.
A1 m 6 7
8 A2
29072SM04
Θ When hydraulic oil pressure (PÝA1) reaches the preset force (FSP) of spring (8), the plunger (6)
moves to the right as shown.
P1ÝA1 = Fsp + P1ÝA2
Fsp
P1=
A1 - A2
P=P1
29072SM06
2-52
Ι When the pressure of chamber g reaches the preset force (Fsp) of spring (8), the piston (7)
moves right and stop the piston (7) hits the end of body.
m 6 7 f g
P=P1
29072SM07
Κ When piston (7) hits the end of body, it stops moving to the right any further. As the result, the
pressure in chamber (g) equals (Ps).
PsÝA1 = Fsp + PsÝA3
Fsp
Ps =
A1 - A3
m 6 7 g
P=P1
29072SM08
2-53
4) BRAKE SYSTEM
(1) Control valve swing brake system
This is the brake system to stop the swing motion of the excavator during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.
Work Deceleration Stop
A B A B A B
MCV MCV MCV
MCV A, B opened MCV A, B throttled MCV A, B closed
(2) Mechanical swing parking brake system

The mechanical swing parking brake system is installed to prevent the upper structure from
swinging downhill because of its own weight when the excavator is parked on a slope since it
completely eliminates the hydraulic drift of swing motion while the excavator is on a slop, work
can be done more easily and safely.
Η Brake assembly
Circumferential rotation of separate plate
(110) is constrained by the groove
located at casing (101). When housing
is pressed down by brake spring (118)
through friction plate (109), separate
plate (110) and brake piston (119),
friction force occurs there.
Cylinder block (108) is constrained by
this friction force and brake acts, while
brake releases when hydraulic force
exceeds spring force.
32092SM04
101 Casing 110 Separate plate

108 Cylinder block 118 Brake spring
109 Friction plate 119 Brake piston
2-54
Θ Operating principle
a. When the swing control lever (1) is set to the swing position, the each spool is shifted to left or
right and the pilot oil flow is blocked. Then the pilot oil go to SH of the time delay valve (3).
This pressure moves spool (5) to the leftward against the force of the spring(8), so pilot pump
charged oil (P3) goes to the chamber G through port PG.
This pressure is applied to move the piston (119) to the upward against the force of the spring
(118). Thus, it releases the brake force.
3
SH
5
PG
118
G
119
8
1 Swing control lever

2 Main control valve
3 Time delay valve P3
5 Spool
8 Spring
2
118 Brake spring
119 Brake piston
32092SM05
2-55
b. When the swing control lever (1) is set the neutral position, the spool (5) returns to right.
Then, the piston (119) is moved lower by spring (118) force and the return oil from the chamber
G flows back to tank port.
At this time, the brake works.
3
SH
PG
118
G
8
119
1 Swing control lever

2 Main control valve
3 Time delay valve P3
5 Spool
8 Spring 2
118 Brake spring
119 Brake piston
32092SM06
2-56
GROUP 4 TRAVEL DEVICE
1. CONSTRUCTION
Travel device consists travel motor and gear box.
Travel motor includes brake valve, parking brake and high/low speed changeover mechanism.
A B
A,B
N
Am Bm
A Dr
Dr
Dr
Pi
Pi
Dr Dr
FILL
Pi
Pi
HEAVY INDUSTRIES CO.,LTD.
P A R T NO. : 31N8-40070
SERIAL NO. : SBTR-
LEVEL
N
IC
SB
DRAIN
Am Bm
VIEW A
300072TM01A
AB Port Port name Port size

CIRCUIT DIAGRAM A, B Valve port SAE 6000psi 1"
Pi 2 speed control port PF 1/4
Dr Drain port PF 1/2
Am, Bm Gauge port PF 1/4
N Parking release port PF 1/4
2-57
2. SPECIFICATION
1) TRAVEL MOTOR
89-4 89-3 89-2 89-9 89-6 88-6 88-4 88-2 93 88-3 88-5 86 85 87 83 13 14 15 16 25 24 6 28 30 31 4 40 39 43 38 37 71 42 41 47 50
89-5 29
89-6 35
89-9
90-2 32
90-3 33
90-4 A 27
97 21
92 49
90-5
101 75,76
98 48
100 36
11 46
102
73 34
74 44
12
45
91
96
56
89-8 67
89-7
62
90-1 A
99
88-8
63
89-1
65
88-7 103 95 94 88-1 5 72 9 8 7 10 84 23 22 82 17 18 19 1 20 26 3 69 2 68 61 64 60 66 57 58,59 70 55 54 53 52 51
SECTION A-A
29092TM30
1 Casing 16 Plate 31 Ring 46 Back up ring 61 O-ring 83 Housing 89-1 Carrier No.2 91 Sun gear No.1
2 Plug 17 Piston 32 Spring 47 Cap 62 Lock screw 84 Bearing 89-2 Planetary gear No.2 92 Plug
3 Screw 18 Stopper 33 Valve casing 48 Cap 63 Nut 85 Shim 89-3 Needle No.2 93 Lock pin
4 Screw 19 O-ring 34 Needle bearing 49 Bolt 64 Spool 86 Retainer 89-4 Thrust washer No.2 94 Ring gear
5 Pin 20 Back up ring 35 O-ring 50 Socket bolt 65 Plug 87 Bolt 89-5 Pin No.2 95 Bolt
6 Pin 21 Cylinder block 36 Pin 51 Seat 66 O-ring 88 Carrier No.3 89-6 Spring pin No.2 96 Thrust ring No.1
7 Stopper 22 Cylinder spring 37 Spool 52 Steel ball 67 Valve plate 88-1 Carrier No.3 89-7 Sun gear No.2 97 Cover
8 O-ring 23 Spacer 38 Screw 53 Stopper 68 Spring 88-2 Planetary gear No.3 89-8 Snap ring No.2 98 Thrust ring No.2
9 Back up ring 24 Guide 39 Damping check 54 Plug 69 O-ring 88-3 Needle No.3 89-9 Spring pin No.2 99 Bolt
10 Piston 25 Plate 40 Spring 55 O-ring 70 Socket bolt 88-4 Thrust washer No.3 90 Carrier No.1 100 Motor ring
11 Shaft 26 Piston & Shoe assy 41 O-ring 56 Plug 71 Socket bolt 88-5 Pin No.3 90-1 Carrier No.1 101 Thrust ring No.3
12 Spacer 27 Plate 42 Plunger 57 Relief valve 72 Lock screw 88-6 Spring pin No.3 90-2 Planetary gear No.1 102 Pad
13 Roller bearing 28 Plate 43 Spring 58 O-ring 73 Oil seal 88-7 Sun gear No.3 90-3 Needle bearing No.1 103 Coupling
14 Stop ring 29 Brake 44 Stopper 59 Back up ring 74 Lock ring 88-8 Snap ring No.3 90-4 Thrust washer No.1
15 Support 30 Ring 45 O-ring 60 Rod 82 Floating Seal 89 Carrier No.2 90-5 Pin No.1
2-58
3. PRINCIPLE OF DRIVING
1) WORKING OF ROTARY GROUP
The high pressurized hydraulic oil which is supplied from a hydraulic pump is flows into a cyl-
inder block (21) through the valve casing (33) of motor, and valve plate (67).
The rotary group has a construction that the above high pressurized hydraulic oil is flow only
one side of the line Y-Y which connect the upper and lower dead point of the piston (26).
This high pressurized hydraulic oil works on the piston and generating the force F1, F1 = P *
A (P : supplied pressure, A : pressure receving area), like following pictures.
This force, F1, is devided by the swash plate (16) having a tilting angle ɷinto the thrust com-
ponent N1 and radial component W1.
The W1 generates torque, T = W1 * R1, in respect to the line Y-Y.
This torque generated by each piston on the high pressurized hydraulic oil side is summed up
onto a resultant torque ∑ (W1 * R1), which prodeces torque for rotation.
This torque transfers the rotation force to the cylinder block (21) through the pistons.
Since the cylinder block is spline-coupled with the shaft, the rotation force is transmitted to the
shaft accordingly.
W1 Piston
Cylinder
R1
N1
O A
f1 F1 P
W1
High Y Low
pressure pressure
2907A2TM07
2-59
2) WORKING OF RELIEF VALVE
Relief valve carries on two function of following.
(1) Relief valve is to keep the starting pressure of the hydraulic motor at a constant value and bypass
to the return line excessive oil generated at the motor inlet depending upon the acceleration
speed of the inertia object.
(2) In case of an inertia object stopped, relief valve is generating a break pressure at the outlet and
stop it forcedly.
The chamber A is always connect with port A of a motor. When the pressure at port A increase
and the force pushing poppet A is higher than the pressure of the spring, then poppet A is pushed
up from the contact surface of seat A, and oil flows from chamber A to port B.
Port A Port B
Chamber A
Poppet A
2907A2TM04
2-60
1) WORKING OF NEGATIVE BRAKE
The negative brake is released applying to the brake piston (29) the pressure led through built in
the valve casing (33) spool. With no pressure working, the brake force is always ensured.
The brake force is generated by the frictional force among a plate (28) fixed by pin (6) and shaft
casing, brake piston (29) and a frictional plate (27) connected through spline outside the cylinder
block (21).
Without pressure being applied to the brake piston, the brake piston is pushed by ten brake springs
(32) and the friction plate and separator plate are held between the brake piston and casing. This
friction force restrains the shaft (11) spline-coupled with the cylinder block, and thus functions the
brake.
11 6 28 27 29 32 21 33
300072TM05
2-61
4) COUNTERBALANCE VALVE
Av port is connected to a hydraulic pump : Bv port is connected to a tank.
The oil supplied from the hydraulic pump passed through Av → Cv → C sequence, pushed up the
poppet of the check valve, passed through L to port AM, and is supplied to the hydraulic motor to
turn it. But the brake is operated. Therefore, the pump discharge oil pressure is increases. And
the pressure is led via passage G to spring room M. When the pressure in room M exceed the
value equivalent to the force of the spring which holds the spool at its neutral position, the spool
begins to move right.
The oil in room N is sent to room Dv by orifice I and discharged from Bv port to a tank. So spool
moves to the right. The oil flows as the way of K → Dv → Bv sequence. Also according to the oil
path as composed way Cv → H → P sequence, the pressure of Av pump is provided to the port P.
An working oil in room N is discharged through orifice and a gap. Therefore the switching operation
of spool is driving slowly.
When the pump discharge pressure fall, spool moves to the left side by a spring at the side of room
N.
Also spool moves to the left, the hydraulic oil in room M is sent to Cv room through orifice I' and
discharged to the Av port.
When the pressure at port Av fall down to the tank pressure, the pressure of room M is as the
same as that the tank pressure and becomes equal to that in room N, and so the spool returns to
its neutral position.
AM P BM
L K
Check valve
H
M I' I N
G
Cv Dv
Av Bv
300072TM06
2-62
5) WORKING OF DISPLACEMENT CHANGEOVER
The capacity of the travel motor is changed by changing the tilting angle of this swash plate(16).
The tilting angle changes by displacement changeover valve.
(1) External pilot pressure : Pi = 0 (large displacement)
By means of the built-in high pressure selector mechanism in the valve casing (33), the high
pressure oil working on the motor function to port P of the displacement-changeover valve.
A the spool (64) assembled in the displacement changeover valve is pressed to plug (65) by the
spring (68), the high pressure oil at port P flows to port Sb.
This high pressure oil flows through oil passage (passage A') of valve casing (33) and shaft
casing works to chamber A.
This oil in chamber B flows through passage B' and port Sa into the drain line. The displacement
changeover piston (17) is pushed right and the swash plate (16) moves in the arrowed direction
around rotation center 'O'. The swash plate moves until it touched stopper (18), and then is fixed
there.
External pilot
pressure
Chamber A Chamber B Pi = 0
B'
Drain Sa Sb
A'
P
65
7 10 16 17 18 68 64
High pressure oil
Selector valve
29092TM09
2-63
(2) External pilot pressure : Pi ≥ 20 kgf/cm2 (small displacement)
If the force operating on spool (64) of the displacement changeover valve is stronger than the
spring (68), and the spool moves to the left side.
The high pressure oil is works on room B through passage Sa → B' from port P.
The oil in chamber A flows into the drain line through the passage A' → Sb.
The displacement changeover piston (17) is pushed left and the swash plate (16) moves in the
arrowed direction around rotation center 'O'. The swash plate moves until it touches stopper (7),
and then is fixed there.
If the load increase while the motor is working with its small displacement (Pi ≥ 20kgf/cm2, 2nd
speed) until the motor inlet port pressure reaches the preset value, the motor increase its
displacement in response to the load, while maintaining the pressure at the preset value
(automatic 2 -speed function). As motor inlet port pressure reaches the preset value and then
spool (64) moves right side, inlet pressure oil flows into chamber A through port Sb and the
swash plate moves until it touches stopper (17). If the load further increase until the displacement
of the motor reaches the maximum value, the inlet port pressure increase further.
If the load decreases under this condition, the motor continues reducing its displacement in the
reverse sequence. As the load and inlet port pressure decreases and reaches the preset value,
spool (64) moves left side by the pilot pressure (Pi). Therefore inlet port pressure flow into
chamber B through port Sa and the swash plate moves until it touches stopper (10).
External pilot
pressure
2
Chamber A Chamber B Pi 20kgf/cm
B'
Drain Sa Sb
A'
P
65
7 10 16 17 18 68 64
High pressure oil
Selector valve
2907A2TM06
2-64
6) REDUCTION GEAR
(1) Planet
Planetary
ary gear mechanism
Reduction unit slows down the rotating speed of motor and converts motor torque to strong
rotating force.
This reduction unit utilizes two stages, planetary reduction system.
Planetary reduction system consists of sun gear, planetary gears, carriers and ring gear.
When the sun gear (s) is driven through input shaft, planetary pinions (b), rotating on their center,
also move, meshing with fixed ring gear (a), around sun gears (s).
This movement is transferred to carrier (k) and deliver the torque.
This mechanism is called planetary gear mechanism.
Fixed ring gear(a)

Ring gear(a)
Carrier(k)
Planetary pinions(b) Carrier(k)
Sun gear(s)
Input Output
Sun gear(s)
Planetary pinions(b)
2907A2TM11 2907A2TM11
(2) Two stages reduction gear

When the sun gear S1 is driven by input shaft, planetary action occurs among gears S1
S1, a and b
and revolution of gear b transfers the rotation of carrier K1 to second sun gear S2
S2, and also
evokes planetary action between gear S2
S2, a and d.
This time, because carrier K2 is fixed to frame, gear d drives ring gear a and then ring gear a
rotates to drive sprocket.
b d
S1 S2
K1 K2
2907A2TM12
2-65
GROUP 5 RCV LEVER
1. STRUCTURE
The casing has the oil inlet port P (primary pressure) and the oil outlet port T (tank). In addition the
secondary pressure is taken out through ports 1, 2, 3 and 4 provided at the bottom face.
19 Switches
No. LH RH
5 One touch decel Horn
6 Power boost Breaker
5
B
19
25
Single
operation Simultaneous
operation
6
DETAIL B
Tilted direction of
handle(RH)
1 P
T Tilted direction of
connector(LH, RH)
2 3
Tilted direction of
handle(LH)
A VIEW A
Port LH RH Port size

P T
P Pilot oil inlet port Pilot oil inlet port
T Pilot oil return port Pilot oil return port
1 Left swing port Bucket out port
PF 3/8
2 Arm in port Boom down port
3 Right swing port Bucket in port
1 3 2 4 4 Arm out port Boom up port
Hydraulic circuit
3009SH2RL01
2-66
CROSS SECTION
The construction of the pilot valve is shown in the attached cross section drawing. The casing has
vertical holes in which reducing valves are assembled.
The pressure reducing section is composed of the spool (4), spring (6) for setting secondary pres-
sure, return spring (10), stopper (8), spring seat (7, 13) and shim (5). The spring for setting the sec-
ondary pressure has been generally so preset that the secondary pressure is 5 to 20.5 kgf/cm2
(depending on the type). The spool is pushed against the push rod (9, 11) by the return spring.
When the push rod is pushed down by tilting the handle, the spring seat comes down simultaneously
and changes setting of the secondary pressure spring.
2-67
CROSS SECTION
23
25
26
24
22
21
9
19
20 16
17,27
18
14
11 15
8
7
28 10
6
13
5
12
4
3
1
2
Port 1,3 Port 2,4 300E2RL02
1 Case 8 Stopper 15 O-ring 22 Lock nut

2 Plug 9 Push rod 16 Rod seal 23 Handle assembly
3 Bushing 10 Spring 17 Plate 24 Handle bar
4 Spool 11 Push rod 18 Boot 25 Nut
5 Shim 12 Spring 19 Joint assembly 26 Boot
6 Spring 13 Spring seat 20 Swash plate 27 Spring pin
7 Spring seat 14 Plug 21 Adjusting nut 28 Bushing
2-68
2. FUNCTIONS
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and apply-
ing the output pressure (secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port (P) where oil is supplied from hydraulic pump.
(2) Output ports (1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port (T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool (4) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output port pressure oil to tank port T.
The spring (6) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod (9,11) is inserted and can slide in the plug
(14).
For the purpose of changing the displacement of the push rod through the swash plate (20) and
adjusting nut (21) are provided the handle (23) that can be tilted in any direction around the fulcrum
of the universal joint (19) center.
The spring (10) works on the case (1) and spring seat (7, 13) and tries to return the push rod
(9,11) to the zero-displacement position irrespective of the output pressure, securing its resetting to
the center position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-69
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram
shown below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
5 6
3
1
3
P T
2 4
2-70
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-70
(1) Case where handle is in neutral position
10
T 6
P
4
1 3
21092RL03
The force of the spring (6) that determines the output pressure of the pilot valve is not applied to
the spool (4). Therefore, the spool is pushed up by the spring (10) to the position of port (1, 3) in
the operation explanation drawing. Then, since the output port is connected to tank port T only,
the output port pressure becomes equal to tank pressure.
2-71
(2) Case where handle is tilted
11
1 3
21092RL04
When the push rod (11) is stroked, the spool (4) moves downwards.
Then port P is connected with port (1) and the oil supplied from the pilot pump flows through port
(1) to generate the pressure.
When the pressure at port (1) increases to the value corresponding to the spring force set by tilt-
ing the handle, the hydraulic pressure force balances with the spring force. If the pressure at port
(1) increases higher than the set pressure, port P is disconnected from port (1) and port T is con-
nected with port (1). If it decreases lower than the set pressure, port P is connected with port (1)
and port T is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with the inside bottom of the push rod and the output pressure is left to be con-
nected with port P.
2-72
GROUP 6 RCV PEDAL
1. STRUCTURE
The casing (spacer) has the oil inlet port P (primary pressure), and the oil outlet port T (tank). In
addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face.
12.4 12.4
2 1
4 3
Port Port Port size
P T P Pilot oil inlet port

T Pilot oil return port
1 Travel (LH, Forward)
PF 1/4
2 Travel (LH, Backward)
3 Travel (RH, Forward)
1 2 3 4 4 Travel (RH, Backward)
Hydraulic circuit
21092RP01
2-73
CROSS SECTION
The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in
which reducing valves are assembled.
The pressure reducing section is composed of the spool (8), spring (6) for setting secondary
pressure, return spring (10), stopper (9), and spring seat (7). The spring for setting the secondary
pressure has been generally so preset that the secondary pressure is 5 to 19 kgf/cm2 (depending on
the type). The spool is pushed against the push rod (14) by the return spring.
When the push rod is pushed down by tilting pedal, the spring seat comes down simultaneously and
changes setting of the secondary pressure spring.
27 31 30 29 28 33 36 3
32
24
23 25,26
22
16
21 14
38 17
15 18
13
19
12 20
11
9
5 6
35
4 7
10
3
8
37 1 34 2
21092RP02
1 Body(1) 14 Push rod 27 Cam

2 Body(2) 15 Spring pin 28 Bushing
3 Plug 16 Seal 29 Cam shaft
4 Plug 17 Steel ball 30 Set screw
5 Spring seat 18 Spring 31 Set screw
6 Spring 19 Plate 32 Nut
7 Spring seat 20 Snap ring 33 Bellows
8 Spool 21 Plug 34 Space
9 Stopper 22 O-ring 35 O-ring
10 Spring 23 Rod seal 36 O-ring
11 Rod guide 24 Dust seal 37 Socket bolt
12 O-ring 25 Cover 38 Piston
13 Snap ring 26 Socket bolt
2-74
2. FUNCTION
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure (secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port (P) where oil is supplied from hydraulic pump.
(2) Output port (1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port (T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool (8) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output spool to determine the output pressure.
The spring (6) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod (14) is inserted and can slide in the plug (21).
For the purpose of changing th displacement of the push rod through the cam (27) and adjusting
nut (32) are provided the pedal that can be tilted in any direction around the fulcrum of the cam (27)
center.
The spring (10) works on the casing (1) and spring seat (7) and tries to return the push rod (14) to
the zero-displacement position irrespective of the output pressure, securing its resetting to the
center position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-75
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown
below ant the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
36072SF01
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-76
(1) Case where pedal is in neutral position
T 8
P 10
21092RP03
The force of the spring (6) that determines the output pressure of the pilot valve is not applied to
the spool (8). Therefore, the spool is pushed up by the spring (10) to the position of port 2 in the
operation explanation drawing. Then, since the output port is connected to tank port T only, the
output port pressure becomes equal to tank pressure.
2-77
(2) Case where pedal is tilted
14
21092RP04
When the push rod (14) is stroked, the spool (8) moves downwards.
Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port
1 to generate the pressure.
When the pressure at port 1 increases to the value corresponding to the spring force set by tilting
the handle, the hydraulic pressure force balances with the spring force. If the pressure at port 1
increases higher than the set pressure, port P is disconnected from port 1 and port T is
connected with port 1. If it decreases lower than the set pressure, port P is connected with port
1 and port T is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with inside bottom of the push rod and the output pressure is left to be connected
with port P.
2-78
GROUP 1 HYDRAULIC CIRCUIT (CLUSTER TYPE 1)
10 11 8 9
3
SH
36 40
PG
DB 37 35 XBp2
37
B 23 2
C Pi2 PS
PA PB N2
(Pump)
C Pi1 R2
N1
(Pump) PS
XBp1
23
A(CW) B(CCW) PaL
Aa
Ba
XAa2
1 Main pump
XBa1
4 XAa1
XBa2 2 Main control valve
3 Swing motor
Dr3 Dr7
D D
PnA2 4 Travel motor
P P
34 instead of 39,41
XAo
Pis
Pd Ak 5 RCV lever(LH)
REG REG Bo
MA MB MB MA
A1
Ao
Bk
6 RCV lever(RH)
XAo XAk
24 7 RCV pedal
A2
PS
38 XBk
T
PCk 8 Boom cylinder(LH)
XBo
P PbL 9 Boom cylinder(RH)
VB(BW) VA(FW) VA(FW) VB(BW) (XBo Port Drain)
Ab
10 Arm cylinder
P B
11 Bucket cylinder
C
A
Dr D 12 Bb
12 Turning joint
XAb2
Pk XAb1
13 Check valve
XBb1
Psp 14 Check valve
Bs
Pns Dr1
AtL 15 Hydraulic tank
PS 24 As
XAs XAtL
BtL 16 Oil cooler
27 39 A1 A2 P2 A3
XBtL 17 Air breather
XBs
34 P T
Dr6 PS
24 18 Bypass valve
Py
Dr2
T
Btr
Atr
24 19 Strainer
Px PS
P1 XAtr 20 Drain filter
XAo XBo XBtr Pz
21 Solenoid valve
5 6 7 22 Pressure sensor
SWING P T ARM BUCKET P T BOOM 27 P T TRAVEL 23 Pressure sensor
P1 R1 Po P2 PG 47 24 Pressure sensor
25 Shuttle block
T B
(1,A) (3,B) (2,D) (4,E) (3,F) (1,G) (2,H) (4,J)

(2)
XBtL
(1)
XAtL
(4)
XAtr
(3)
XBtr P A
26 Last guard filter
Psv
A1 a4 PS A2 27 Last guard filter

14 13 a1 a2
29 Shockless valve
DR#,dr#
1 22 PS PS 22 32 Tee-shuttle
33 EPPR valve
a b d e f g h j 16
25 34 Solenoid valve
24 c d1 h1 26 35 Accumulator(option)
XBs XAs XAk XBk PS 33 1
Pi2
Psp 29 XAa1 XBa1 XAb1 XBb1
2
17 33 26 (N2 ,MCV) 36 Accumulator(option)
Accumulator
(MCV) Pi1
PS 3
(N1,MCV) 37 Stop valve(option)
Pns Pis Pk Pz E 38 Shuttle valve
21 (MCV) (MCV) (T/Joint) (MCV)
15
a3
39 Solenoid valve(option)
A5 A4 A3 A2 A1 18 PG
Dr A3
B1 Dr3 B3
40 3-way joint(option)
P4 PG(S/Motor)
19 20 41 2-way pedal(option)
P3 PG(MCV)
P2
47 Solenoid valve(option)
P1
T(dr1)
3309S3HC01P
3-1
■ HYDRAULIC CIRCUIT (CLUSTER TYPE 2)
10 11 8 9
3
SH
36 40
PG
DB 37 35 XBp2
37
B
2
PB C Pi2
PA N2
(Pump)
C Pi1 R2
N1
(Pump)
XBp1
A(CW) B(CCW) PaL
Aa
Ba
XAa2
1 Main pump
XBa1
4 XAa1
XBa2 2 Main control valve
3 Swing motor
Dr3 Dr7
D D
PnA2 4 Travel motor
P P
34 instead of 39,41
XAo
Pis
Pd Ak 5 RCV lever(LH)
REG REG Bo
MA MB MB MA
A1
Ao
Bk
6 RCV lever(RH)
XAo XAk
XBk
7 RCV pedal
A2
T
PCk 8 Boom cylinder(LH)
XBo
P PbL 9 Boom cylinder(RH)
VB(BW) VA(FW) VA(FW) VB(BW) (XBo Port Drain)
Ab
10 Arm cylinder
P B
11 Bucket cylinder
C
A
Dr D 12 Bb
12 Turning joint
XAb2
Pk XAb1
13 Check valve
XBb1
Psp 14 Check valve
Bs
Pns Dr1
AtL 15 Hydraulic tank
As
BtL 16 Oil cooler
27 39 A1 XAs XAtL
17 Air breather
XBtL
XBs
41 P T
Dr6 PS
24 18 Bypass valve
A2 Py
Dr2
T
Btr
Atr
24 19 Strainer
Px PS
P
XAtr 20 Drain filter
XAo XBo XBtr Pz
21 Solenoid valve
5 6 7 24 Pressure sensor
SWING P T ARM BUCKET P T BOOM 27 P T TRAVEL 25 Terminal
P1 R1 Po P2 PG 47 26 Last guard filter
27 Last guard filter
T B
(1,A) (3,B) (2,D) (4,E) (3,F) (1,G) (2,H) (4,J)

(2)
XBtL
(1)
XAtL
(4)
XAtr
(3)
XBtr P A
28 Screw coupling
Psv
A1 a4 A2
29 Shockless valve
14 13 a1 a2
34 Solenoid valve
DR#,dr#
1 28 PG PG 28 35 Accumulator(option)
a b d e f g h j
25 36 Accumulator(option)
Accumulator
16
XBs XAs XBa1 XAk XBk XAb1 XBb1 37 Stop valve(option)
29XAa1 26 39 Solenoid valve(option)
Pi1
26 Pi2
Psp 17 (N1,MCV) (N2, MCV) 40 3-way joint(option)
(MCV)
41 2-way pedal(option)
Pns Pk Pz E 47 Solenoid valve(option)
21 (MCV) (T/Joint) (MCV)
15
a3
28
A5 A4 A3 A2 A1 18 PG
Dr B1 Dr3 B3 A3
P4 PG(S/Motor)
19 20
P3 PG(MCV)
P2
P1
T(dr1)
3309S3HC01S
3-2
Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------ 3-1

Group 2 Main Circuit -------------------------------------------------------------------------------------------------------- 3-3
Group 3 Pilot Circuit -------------------------------------------------------------------------------------------------------- 3-6
Group 4 Single Operation ----------------------------------------------------------------------------------------------- 3-14
Group 5 Combined Operation ---------------------------------------------------------------------------------------- 3-24
GROUP 2 MAIN CIRCUIT
The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit.
The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders
and two travel motors.
The swash plate type variable displacement tandem axial piston pump is used as the main pump
and is driven by the engine at ratio 1.0 of engine speed.
1. SUCTION AND DELIVERY CIRCUIT
To cylinders To motors
Main control valve To oil cooler
To hydraulic oil tank
Main pump
Suction filter
Hydraulic oil tank
3-02
The pumps receive oil from the hydraulic tank through a suction filter. The discharged oil from the
pump flows into the control valve and goes out the tank ports.
The oil discharged from the main pump flows to the actuators through the control valve.
The control valve controls the hydraulic functions.
The return oil from the actuators flows to the hydraulic tank through the control valve and the oil
cooler.
3-3
2. RETURN CIRCUIT
Check valve(2)
Full flow filter Oil cooler 1.5kgf/cm2
Main control valve Actuators
Check valve(1)
3.0kgf/cm2
Check valve(3)
1.5kgf/cm2
29073CI01
All oil from each actuator returns to the hydraulic tank through the control valve.
The bypass check valves are provided in the return circuit.
The setting pressure of bypass check valves are 1.5 kgf/cm2 (21psi) and 3.0 kgf/cm2 (43psi). Usually, oil
returns to the hydraulic tank from the left side of control valve through oil cooler.
When oil temperature is low, viscosity becomes higher and flow resistance increases when passing
through the oil cooler. The oil pressure exceeds 3.0 kgf/cm2 (43psi), the oil returns directly to the
hydraulic tank, resulting in the oil temperature being raised quickly at an appropriate level.
When the oil cooler is clogged, the oil returns directly to the hydraulic tank through bypass check
valve (1).
The full-flow filter and bypass relief valve are provided in the hydraulic tank.
The oil from right and left side of control valve is combined and filtered by the return filter. A bypass
relief valve is provided in the full-flow filter.
When the filter element is clogged, the bypass relief valve opens at 1.5 kgf/cm2 (21psi) differential
pressure.
3-4
3. DRAIN CIRCUIT
Travel motor Swing motor
Turning Main pump

joint From return line
dr2 ~ dr8
Hydraulic Spin filter

oil tank
dr1
Check valve
1.5kgf/cm2
R29073CL02
Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil
have to be fed to the hydraulic tank passing through spin filter and full flow filter in the hydraulic tank.
When the drain oil pressure exceed 1.5 kgf/cm2 (21psi), the oil returns to the hydraulic tank directly.
1) TRAVEL MOTOR DRAIN CIRCUIT

Oil leaking from the right and left travel motors comes out of the drain ports provided in the
respective motor casing and join with each other. These oils pass through the turning joint and
return to the hydraulic tank after being filtered by full flow filter in the hydranlic tank.
2) SWING MOTOR DRAIN CIRCUIT
Oil leaking from the swing motor come out and return to the hydraulic tank passing through a spin
filter.
3) MAIN PUMP DRAIN CIRCUIT
Oil leaking from main pump come out and return to the hydraulic tank passing through spin filter.
3-5
GROUP 3 PILOT CIRCUIT
Remote control valve RCV pedal Remote control valve

(LH lever) (RH lever)
Swing parking brake

MCV Safety lock
solenoid valve
Travel speed solenoid valve
Power boost solenoid valve
Main pump Max flow cut off valve
Line filter Swing speed reducing

solenoid valve
Relief valve
2
40kgf/cm
Pilot pump Suction filter
32093CI01
The pilot circuit consists of suction circuit, delivery circuit and return circuit.
The pilot pump is provided with relief valve, receives the oil from the hydraulic tank through the
suction filter.
The discharged oil from the pilot pump flows to the remote control valve through line filter, EPPR
valve, solenoid valve assemblies, swing parking brake, main control valve and safety lock solenoid
valve.
3-6
1. SUCTION, DELIVERY AND RETURN CIRCUIT
ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER
TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR
PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
RCV PEDAL P T TRAVEL
P1 R1 Po P2 PG
A1 A2
(2) (1) (4) (3) Dr#, dr#

XBtL XAtL XAtr XBtr
FRONT REAR PILOT
PUMP PUMP PUMP
SWING P T ARM BUCKET P T BOOM
SAFETY
Pns Pis Pk Pz SOLENOID
(MCV) (MCV) (T/Joint) (MCV) VALVE
A5 A4 A3 A2 A1
PG
P4 (S/Motor)
P3 PG(MCV)
(1) (3) (2) (4) (3) (1) (2) (4) P2 Psv(PUMP) HYDRAULIC TANK
a b d e f g h j T
d1 P1
(dr1)
c h1
LINE FILTER
XBs XAs XAk XBk PS
Psp XBa1 XAb1 XBb1
PS XAa1
3309S3HC02
The pilot pump receive oil from the hydraulic tank. The discharged oil from the pilot pump flows to the
safety solenoid valve through the line filter. The oil is filtered by the line filter. The pilot relief valve is
provided in the pilot pump for limiting the pilot circuit pressure.
The oil filtered by line filter flows remote control valve through safety solenoid valve.
The return oil flow into the hydraulic tank.
3-7
2. SAFETY VALVE (SAFETY LEVER)
ARM BUCKET BOOM
TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR
PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Btr Dr2 Py
Atr TRAVEL(RH) PS
Px
XAtr
SH
RCV PEDAL P T TRAVEL XBtr Pz
P1 R1 Po P2 PG
(2) (1) (4) (3) A1 A2

XBtL XAtL XAtr XBtr Dr#, dr#
SWING ARM BUCKET BOOM FRONT REAR PILOT

P T P T PUMP PUMP PUMP
SAFETY
Pns Pis Pk Pz SOLENOID
(MCV) (MCV) (T/Joint) (MCV) VALVE
A5 A4 A3 A2 A1 LEVER UP
PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4) P3 PG(MCV)
P2 Psv(PUMP) HYDRAULIC TANK
a b d e f g h j
d1
c h1 T P1
(dr1) LINE FILTER
XBs XAs XAk XBk PS
Psp XBa1 XAb1 XBb1 LEVER DOWN
PS XAa1
3309S3HC03
When the lever of the safety solenoid valve is moved upward, oil flows into the remote control valve
through solenoid valve and line filter.
When the lever of the safety solenoid valve is moved downward, oil does not flows into the remote
control valve, because of blocked port.
3-8
3. BOOM PRIORITY SYSTEM
ARM BUCKET BOOM
TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR
PbL
Ab
PnA2
Boom speed(Cluster type 1) BOOM 2
PCk
XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
P1 R1 Po P2 PG
(2) (1) (4) (3) A1 A2


BOOM PRIORITY
EPPR VALVE
Pns Pis Pk Pz
(MCV) (MCV) (T/Joint) (MCV)
A5 A4 A3 A2 A1
PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4) P3 PG(MCV)
a b d e f g h j
d1
c h1 T P1
(dr1) LINE FILTER
XBs XAs XAk XBk PS
Psp XBa1 XAb1 XBb1
PS XAa1 3309S3HC04
When carrying out the combined operation of swing and boom up, the boom up operating speed is
lowered then normal operation.
To increase working efficiency, swing speed reducing system is used.
The pilot oil from pilot pump flow into Pns port in main control valve through boom priority EPPR
valve. Pns oil pressure moves swing reducing spool to lower position and oil flow rate to the swing
motor decreased.
Then, the boom up speed is increased. This is called the boom priority system.
The boom up speed can be adjusted by the cluster. Refer to page 3-12 of the operator's manual.
3-9
4. TRAVEL SPEED CONTROL SYSTEM
ARM BUCKET BOOM
TRAVEL MOTOR
XBp2
D P P D
REG REG
Pi2 PS N2
(Pump)
MA MB MB MA Pi1
(Pump) PS N1 R2
XBp1
PaL
VB(BW) VA(FW) VA(FW) VB(BW)

Aa
PaL
XBa2
Ba
ARM 2
ARM 1
A P B XBa1 XAa2
C Dr D
XAa1 XBa2
Pk XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR
PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Btr Dr2 Py
Atr TRAVEL(RH) PS
Px
XAtr
SH
P1 R1 Po P2 PG
(2) (1) (4) (3) A1 A2


TRAVEL SPEED
SOLENOID VALVE
Pk
Pns Pis (T/Joint) Pz
(MCV) (MCV) (MCV)
A5 A4 A3 A2 A1
PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4) P3 PG(MCV)
a b d e f g h j
d1
c h1 T P1
(dr1) LINE FILTER
XBs XAs XAk XBk PS
Psp XBa1 XAb1 XBb1
PS XAa1 3309S3HC05
When the travel speed switch is pushed, the travel speed solenoid valve is actuated and the
discharged oil from the pilot pump flows to the P port of pilot valve in the travel motors.
As a result, the control piston is pushed by the main oil flow, thus the displacement is minimized.
When the travel speed switch is pushed once more, the travel speed solenoid valve is return to
original position by the force of spring, the hydraulic oil of P port returns to the hydraulic tank.
As a result, the control piston is returned by the main oil flow, thus the displacement is maximized.
3-10
5. MAIN RELIEF PRESSURE CHANGE CIRCUIT
ARM BUCKET BOOM
TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR
PbL
Ab
PnA2
PCk
BOOM 2 XAb1
Auto power boost(Cluster type 1) XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
P1 R1 Po P2 PG
(2) (1) (4) (3) A1 A2


Pz
Pns Pis Pk (MCV)
(MCV) (MCV) (T/Joint)
A5 A4 A3 A2 A1
PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4) P3 PG(MCV)
a b d e f g h j
d1
c h1 T P1
(dr1)
XBs XAs XAk XBk PS
Psp XBa1 XAb1 XBb1 LINE FILTER
PS XAa1 3309S3HC06
When the power boost switch on the left control lever is pushed ON, the power boost solenoid valve
is actuated, the discharged oil from the pilot pump flows into Pz port of the main relief valve of main
control valve; then the setting pressure of the main relief valve is raised from 350 kgf/cm2 to
380 kgf/cm2 for increasing the digging power.
And even when pressed continuously, it is canceled after 8 seconds.
When the auto power boost function is selected to enable on the cluster, the pressure of the main
relief pressure is automatically increased to 380 kgf/cm2 as working condition by the MCU. It is
operated max 8 seconds.
3-11
6. ARM REGENERATION CUT SYSTEM (CLUSTER TYPE 1)
ARM BUCKET BOOM
TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR
PbL
Ab
PnA2
PCk
Arm regeneration(Cluster type 1) BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Btr Dr2 Py
Atr TRAVEL(RH) PS
Px
XAtr
SH
P1 R1 Po P2 PG
(2) (1) (4) (3) A1 A2


ARM REGENERATION
SOLENOID VALVE
Pns Pis Pk Pz
A5 A4 A3 A2 A1
PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4) P3 PG(MCV)
a b d e f g h j
d1
c h1 T P1
(dr1) LINE FILTER
XBs XAs XAk XBk PS
Psp XBa1 XAb1 XBb1
PS XAa1 3309S3HC07
When the arm regeneration is selected to disable on the cluster, the arm regeneration solenoid
valve is activated. The pilot oil from pilot pump flow into Pis port in main control valve through
solenoid valve and the arm regeneration spool is shifted to left.
Then, the oil from arm regeneration passage returns to tank and the arm regeneration function is
deactivated.
When the arm regeneration is selected to enable on the cluster, the arm regeneration function is
activated and arm in operation speed is increased.
Refer to page 2-29 for the arm regeneration function.
3-12
7. SWING PARKING BRAKE RELEASE
ARM BUCKET BOOM
TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Ba Aa
PaL
XBa2
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
SWING MOTOR
XAa2
Dr3 Dr7
PnA2
SH Pis
Pd Ak
Bo
PG Ao XBp1 Bk
OPTION BUCKET
XAo XAk
DB XBk
XBo PCk
PbL
PA PB
Ab
C PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
A(CW) B(CCW) Pns Dr1

Bs TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
P1 R1 Po P2 PG
(2) (1) (4) (3) A1 A2


Pns Pis Pk Pz
A5 A4 A3 A2 A1
PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4) P3 PG(MCV)
a b d e f g h j
d1
c h1 T P1
XAk XBk PS (dr1)
XBs XAs XBa1 XAb1 XBb1 LINE FILTER
Psp
XAa1
PS 3309S3HC08
When one of the RCV lever (except travel lever) is tilted, the pilot oil flows into SH port through main
control valve.
This pressure moves spool so, discharged oil from pilot valve flows to swing motor PG port.
This pressure is applied to swing motor disc, thus the brake is released.
When all of the RCV lever are set in the neutral position, oil in the swing motor disc cylinder is
drained, thus the brake is applied.
3-13
GROUP 4 SINGLE OPERATION
1. BOOM UP OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR
PbL
Relief valve
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
P1 R1 Po P2 PG
HYDRAULIC TANK A1 A2
FRONT REAR PILOT

PUMP PUMP PUMP
3309S3HC09
When the right control lever is pulled back, the boom spools in the main control valve are moved to
the up position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of boom cylinders.
At the same time, the oil from the small chamber of boom cylinders returns to the hydraulic oil tank
through the boom spool in the main control valve. When this happens, the boom goes up.
The excessive pressure in the boom cylinder head side is prevented by relief valve.
When the boom is up and the control lever is returned to neutral position, the circuit for the holding
pressure at the bottom end of the boom cylinder is closed by the boom holding valve.
This prevents the hydraulic drift of boom cylinder.
3-14
2. BOOM DOWN OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR PbL
Relief valve
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
P1 R1 Po P2 PG
FRONT REAR PILOT

PUMP PUMP PUMP
3309S3HC10
When the right control lever is pushed forward, the boom 1 spools in the main control valve are
moved to the down position by the pilot oil pressure from the remote control valve.
The oil from the rear pump flows into the main control valve and then goes to the small chamber of
boom cylinders. At the same time, the oil from the large chamber of boom cylinders returns to the
hydraulic tank through the boom spool in the main control valve.
When the down speed of boom is faster, the oil returned from the large chamber of boom cylinder
combines with the oil from the rear pump, and flows into the small chamber of the boom cylinder.
This prevents cylinder cavitation by the negative pressure when the rear pump flow can not match
the boom down speed. And the excessive pressure in the boom cylinder rod side is prevented by
the relief valve.
3-15
3. ARM IN OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
Make up PaL
valve
Relief Aa
PaL valve
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
P1 R1 Po P2 PG
FRONT REAR PILOT

PUMP PUMP PUMP
3309S3HC11
When the left control lever is pulled back, the arm spools in the main control valve are moved to the
roll in position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of arm cylinder.
At the same time, the oil from small chamber of arm cylinder returns to the hydraulic oil tank through
the arm spool in the main control valve. When this happens, the arm rolls in.
The excessive pressure in the arm cylinder head side is prevented by relief valve.
The cavitation which will happen to the head side of the arm cylinder is also prevented by the make-
up valve in the main control valve.
3-16
4. ARM OUT OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
Make up
Arm holding valve
valve
PaL
Relief
valve Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns TRAVEL(LH) Dr1 AtL

As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
P1 R1 Po P2 PG
FRONT REAR PILOT

PUMP PUMP PUMP
3309S3HC12
When the left control lever is pushed forward, the arm spools in the main control valve are moved to
the roll out position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the small
chamber of arm cylinder.
At the same time, the oil from the large chamber of arm cylinder returns to the hydraulic oil tank
through the arm spools in the main control valve. When this happens, the arm rolls out.
The excessive pressure in the arm cylinder rod side is prevented by relief valve.
When the arm is roll out and the control lever is returned to neutral position, the circuit for the holding
pressure at the rod side of the arm cylinder is closed by the arm holding valve.
The cavitation which will happen to the rod side of the arm cylinder is also prevented by the make-up
valve in the main control valve.
3-17
5. BUCKET IN OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
Make up
XAa2 valve
Dr3 Dr7
PnA2
Pis Relief
Pd valve Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
P1 R1 Po P2 PG
A1 A2
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
3309S3HC13
When the right control lever is pulled left, the bucket spool in the main control valve is moved to the
roll in position by the pilot oil pressure from the remote control valve.
The oil from the rear pump flows into the main control valve and then goes to the large chamber of
bucket cylinder. The oil form the front pump flows into the large chamber of bucket cylinder through
confluence oil passage in the main control valve by bypass cut pilot pressure (XBp1).
At the same time, the oil from the small chamber of bucket cylinder returns to the hydraulic oil tank
through the boom spool in the main control valve. When this happens, the bucket rolls in.
The excessive pressure in the bucket cylinder head side is prevented by relief valve.
The cavitation which will happen to the head side of the bucket cylinder is also prevented by the
make-up valve in the main control valve.
3-18
6. BUCKET OUT OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Make Dr7
up valve PnA2
Pis
Relief
Pd valve Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
P1 R1 Po P2 PG
FRONT REAR PILOT

PUMP PUMP PUMP
3309S3HC14
When the right control lever is pushed right, the bucket spool in the main control valve is moved to
the roll out position by the pilot oil pressure from the remote control valve.
The oil from the rear pump flows into the main control valve and then goes to the small chamber of
bucket cylinder.
At the same time, the oil from the large chamber of bucket cylinder returns to the hydraulic oil tank
through the bucket spool in the main control valve. When this happens, the bucket rolls out.
The excessive pressure in the bucket cylinder rod side is prevented by relief valve.
The cavitation which will happen to the rod side of the bucket cylinder is also prevented by the make-
up valve in the main control valve.
3-19
7. SWING OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
XBp2
Pi2 PS
(Pump) N2
Pi1
(Pump) PS N1 R2
XBp1
PaL
Ba Aa
PaL
XBa2
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
SWING MOTOR
XAa2
Dr3 Dr7
PnA2
SH
Pis
Pd Ak
Bo
PG Ao XBp1 Bk
OPTION BUCKET
XAo XAk
DB XBk
XBo PCk
PbL
PA PB
Ab
C PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
A(CW) B(CCW) Pns Dr1

Bs TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Btr Dr2 Py
Atr TRAVEL(RH) PS
Px
XAtr
RCV PEDAL TRAVEL SH
P T XBtr Pz
P1 R1 Po P2 PG
(2) (1) (4) (3) A1 A2

SWING P T ARM BUCKET P T BOOM FRONT REAR PILOT

PUMP PUMP PUMP
Pns Pis Pk Pz
A5 A4 A3 A2 A1
PG
(1) (3) (2) (4) (3) (1) (2) (4) P4 (S/Motor)
P3 PG(MCV)
a b d e f g h j P2 Psv(PUMP) HYDRAULIC TANK
d1
c h1 T P1
PS XAk XBk PS (dr1)
XBs XAs XBa1 XAb1 XBb1 LINE FILTER
Psp
PS XAa1 3309S3HC15
When the left control lever is pushed left or right, the swing spool in the main control valve is moved
to the left or right swing position by the pilot oil pressure from the remote control valve.
Also the swing operation preference function is operated by the pilot pressure Psp (refer to page
2-36).
The oil from the front pump flows into the main control valve and then goes to the swing motor.
At the same time, the return oil from the swing motor returns to the hydraulic oil tank through the
swing spool in the main control valve.
When this happens, the upper structure swings to the left or right.
The swing parking brake, make up valve and the motor brake valve are provided in the swing motor.
The cavitation which will happen to the swing motor is also prevented by the make up valve in the
swing motor itself.
3-20
SWING CIRCUIT OPERATION
PARKING BRAKE
SWING MOTOR DEVICE
BRAKE RELEASE VALVE
SH
BRAKE OFF
MAKE UP VALVE
PG
DB
BRAKE ON
PA PB
MAKE UP
PORT(C)
MOTOR BRAKE VALVE ANTI-INVERSION VALVE
A(CW) B(CCW)
TO/FROM MAIN CONTROL VALVE
3309S3HC16
1) MOTOR BRAKE VALVE

Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing
operation and controls the swing motor operating pressure.
2) MAKE UP VALVE
The make up valves prevent cavitation by supplying return oil to the vacuum side of the motor.
3) PARKING BRAKE
This is function as a parking brake only when all of the RCV lever (except travel pedal) are not
operated.
PARKING BRAKE "OFF" OPERATION
The parking brake is released by the pilot pressure oil from the pilot pump.
When the RCV lever placed in the operating position, the pilot oil flows into SH port through the
MCV. This pressure transferred to the brake release valve and the brake release valve is change
over. Then the pilot oil pressure PG lift the brake piston and release the parking brake.
PARKING BRAKE "ON" OPERATION
When all of the RCV lever placed in the neutral position, the pressure of the pilot oil passage down.
Then the brake release valve returned to the neutral position and the oil is returned from the brake
piston to the tank. And the brake is set to 'ON".
4) ANTI-INVERSION VALVE
This anti-inversion valve absorbs shocks produced as swing motion stops and reduced oscillation
cause by swing motion.
3-21
8. TRAVEL FORWARD AND RE
REVERSE
VERSE O
OPERATION
PERATION
ARM BUCKET BOOM
TRAVEL MOTOR
XBp2
D P P D
Pi2 PS N2
REG REG
(Pump)
MA MB MB MA Pi1
(Pump) PS N1 R2
XBp1
PaL
VB(BW) VA(FW)
Aa
VA(FW) VB(BW)
PaL
XBa2
Ba
ARM 2
ARM 1
TURNING XBa1 XAa2
JOINT XAa1 XBa2
Pk XAa2
Dr Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1 AtL

TRAVEL(LH)
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
P1 R1 Po P2 PG
(2) (1) (4) (3) A1 A2


TRAVEL SPEED
SOLENOID VALVE
Pk
Pns Pis (T/Joint) Pz
(MCV) (MCV) (MCV)
A5 A4 A3 A2 A1
PG
P4 (S/Motor)
(1) (3) (2) (4) (3) (1) (2) (4) P3 PG(MCV)
a b d e f g h j
d1
c h1 T P1
(dr1) LINE FILTER
XBs XAs PS XAk XBk PS
Psp XBa1 XAb1 XBb1
PS XAa1 3309S3HC17
When the travel levers are pushed forward or reverse position, the travel spools in the main control
valve are moved to the forward or reverse travel position by the pilot oil pressure from the remote
control valve.
The oil from the each pump flows into the main control valve and then goes to the each travel motor
through the turning joint.
The return oil from both travel motors returns to the hydraulic oil tank through the turning joint and
the travel spools in the main control valve.
When this happens, the machine moves to the forward or reverse.
3-22
TRAVEL CIRCUIT OPERATION
TRAVEL MOTOR DEVICE
D D
P P
OVERLOAD REG REG

RELIEF VALVE
MA MB MB MA
VB VA VA VB
TURNING JOINT
Pk COUNTER BALANCE
Dr VALVE
TO/FROM MAIN CONTROL VALVE
3309S3HC18
Valves are provided on travel motors to offer the following functions.
1) COUNTER BALANCE VALVE

When stopping the motor of slope descending, this valve to prevent the motor over run.
2) OVERLOAD RELIEF VALVE
Relief valve limit the circuit pressure below 350 kgf/cm2 to prevent high pressure generated at a time
of stopping the machine. Stopping the motor, this valve sucks the oil from lower pressure passage
for preventing the negative pressure and the cavitation of the motor.
3-23
GROUP 5 COMBINED OPERATION
1. OUTLINE
ARM BUCKET BOOM
TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Btr Dr2 Py
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
P1 R1 Po P2 PG
STRAIGHT REAR PILOT
TRAVEL
FRONT
PUMP PUMP PUMP
SPOOL
3309S3HC19
The oil from the front and rear pump flows through the neutral oil passage, bypass oil passage and
confluence oil passage in the main control valve. Then the oil goes to each actuator and operates
them. Check valves and orifices are located on these oil passage in the main control valve. These
control the oil from the main pumps so as to correspond to the operation of each actuator and
smooth the combined operation.
STRAIGHT TRAVEL SPOOL

This straight travel spool is provided in the main control valve.
If any actuator is operated when traveling, the straight travel spool is pushed to the right by the pilot
oil pressure.
Consequently, the left and right travel oil supply passage are connected, and equivalent amount of
oil flows into the left and right travel motors. This keeps the straight travel.
3-24
2. COMBINED SWING AND BOOM UP OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
P1 R1 Po P2 PG
FRONT REAR PILOT

PUMP PUMP PUMP
3309S3HC21
When the swing and boom up functions are operated, simultaneously the swing spool and boom
spools in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve.
The oil from the front pump flows into the swing motor through swing spool and the boom cylinder
through boom 2 spool.
The oil from the rear pump flows into the boom cylinders through the boom 1 spool in the right
control valve. The upper structure swings and the boom is operated.
Refer to page 3-8 for the boom priority system.
3-25
3. COMBINED SWING AND ARM OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
P1 R1 Po P2 PG
FRONT REAR PILOT

PUMP PUMP PUMP
3309S3HC22
When the swing and arm functions are operated, simultaneously the swing spool and arm spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve.
The oil from the front pump flows into the swing motor through swing spool and the arm cylinder
through arm 1 spool.
The oil from the rear pump flows into the arm cylinder through the arm 2 spool of the right control
valve. The upper structure swings and the arm is operated.
Refer to page 2-35 for the swing operation preference function.
3-26
4. COMBINED SWING AND BUCKET OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Btr Dr2 Py
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
P1 R1 Po P2 PG
FRONT REAR PILOT

PUMP PUMP PUMP
3309S3HC23
When the swing and bucket functions are operated, simultaneously the swing spool and bucket
spool in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve.
The oil from the front pump flows into the swing motor through the swing spool in the left control
valve.
The oil from the rear pump flows into the bucket cylinder through the bucket spool in the right control
valve.
The upper structure swings and the bucket is operated.
3-27
5. COMBINED SWING AND TRAVEL OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
P1 R1 Po P2 PG
STRAIGHT FRONT REAR PILOT

TRAVEL PUMP PUMP PUMP
SPOOL
3309S3HC24
When the swing and travel functions are operated, simultaneously the swing spool and travel spools
in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve and straight travel spool is pushed to the right by the pilot oil pressure from the
pilot pump.
The oil from the front pump flows into the travel motors through the RH travel spool of the left control
valve and the LH travel spool of the right control valve via the straight travel spool.
The oil from the rear pump flows into the swing motor through the swing spool and travel motor
through the LH travel spool via the check valve and orifice in the straight travel spool.
The upper structure swings and the machine travels straight.
3-28
6. COMBINED BOOM AND TRAVEL OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao Bk
OPTION BUCKET XBp1
XAo XAk
XBo XBk
PCk
SWING MOTOR PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1 AtL

TRAVEL(LH)
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
P1 R1 Po P2 PG
SPOOL
3309S3HC25
When the boom and travel functions are operated, simultaneously the boom spools and travel spools
in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve and the straight travel spool is pushed to the right by the oil pressure from pilot
pump.
The oil from the rear pump flows into the boom cylinders through the boom 2 spool and boom 1
spool via the parallel and confluence oil passage in case boom up operation. Also, the oil from the
rear pump flows into the travel motors through the LH travel spool via the check valve and orifice in
the straight travel spool.
The boom is operated and the machine travels straight.
3-29
7. COMBINED ARM AND TRAVEL OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
P1 R1 Po P2 PG
A1 A2
HYDRAULIC TANK
SPOOL
3309S3HC26
When the arm and travel functions are operated, simultaneously the arm spools and travel spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve and the straight travel spool is pushed to the right by the oil pressure from pilot pump.
The oil from the rear pump flows into the arm cylinders through the arm 1 spool and arm 2 spool via
the parallel and confluence oil passage. Also, the oil from the rear pump flows into the travel motors
through the LH travel spool via the check valve and orifice in the straight travel spool.
The arm is operated and the machine travels straight.
3-30
8. COMBINED BUCKET AND TRAVEL OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
P1 R1 Po P2 PG

SPOOL
3309S3HC27
When the bucket and travel functions are operated, simultaneously the bucket spool and travel
spools in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve, and the straight travel spool is pushed to the right by the oil pressure from pilot
pump. The oil from the front pump flows into the travel motors through the RH travel spool of the left
control valve and the LH travel spool of the right control valve via the straight travel spool of the
control valve.
The oil from the rear pump flows into the bucket cylinder through the bucket spool via the confluence
oil passage. Also, the oil from the rear pump flows into the travel motors through the LH travel spool
via the check valve and orifice in the straight travel spool.
The bucket is operated and the machine travels straight.
3-31
9. COMBINED BOOM UP AND BUCKET OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
XBp2
Pi2 PS N2
(Pump)
Pi1
(Pump) PS N1 R2
XBp1
PaL
Aa
PaL
XBa2
Ba
ARM 2
ARM 1
XBa1 XAa2
XAa1 XBa2
XAa2 Bucket in strock
limiter spool
Dr3 Dr7
PnA2
Pis
Pd Ak
Bo
Ao XBp1 Bk
OPTION BUCKET
XAo XAk
XBo XBk
PCk
SWING MOTOR PbL
Ab
PnA2
PCk
BOOM 2 XAb1
XAb2 BOOM 1 XAb2 Bb
PbL
XBb1
Psp
Bs Pns Dr1
TRAVEL(LH) AtL
As SWING
BtL
XAs XAtL
XBs XBtL
Dr6 PS
Dr2 Py
Btr
Atr TRAVEL(RH) PS
Px
XAtr
SH
XBtr Pz
P1 R1 Po P2 PG
FRONT REAR PILOT

PUMP PUMP PUMP
3309S3HC28
When the boom up and bucket functions are operated, simultaneously each spool in the main
control valve is moved to the functional position by the pilot oil pressure from the remote control
valve. Also, the boom up operation preference function is operated by the pilot pressure PCk (refer
to page 2-33).
The oil from the front pump flows into the boom cylinders through the boom 2 spool in the left control
valve. The oil from the rear pump flows into the boom cylinders and bucket cylinder through the
boom 1 spool, bucket spool and the parallel and confluence oil passage in the right control valve.
The boom and bucket are operated.
3-32
Group 1 Component Location ----------------------------------------------------------------------------------------- 4-1

Group 2 Electrical Circuit -------------------------------------------------------------------------------------------------- 4-3
Group 3 Electrical Component Specification ------------------------------------------------------------------ 4-38
Group 4 Connectors --------------------------------------------------------------------------------------------------------- 4-46
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
26 25
27 24
28 23
29 22
30
17
B
A
C
CLUSTER TYPE 1
17
21
20
19
1
18
2 Y
R
G
3 MO
PA DEL
RT : R2
NO 90L
: 21Q C-9
8-3 BH
273
0
4
5
6 Electric box
7
8
9
10
15
14
13
12 CN-16&16A
CN-16B
11
16
3309S4EL01
1 Cigar light 11 Power max switch 21 MCU

2 Aircon & heater switch panel 12 Emergency engine stop switch 22 USB socket
3 Accel dial switch 13 One touch decel switch 23 Overload switch
4 Horn switch 14 Fuse box 24 Beacon switch
5 Breaker operation switch 15 Master switch 25 Quick clamp switch
6 Air compressor switch 16 Emergency engine connector 26 Cab light switch
7 Starting switch 17 RS232 service socket 27 Travel alarm switch
8 Cluster 18 Radio & USB player 28 Washer switch
9 Service meter 19 Heated seat switch 29 Wiper switch
10 Safety lever 20 Speaker 30 Main light switch
4-1
2. LOCATION 2
25 4
22 1
1
1
1 24
BOOM COUNTERWEIGHT SOLENOID VALVE CAB
2 8 9 10 23
12
a4
13
a3 14
a2 15
a1
16
3
26 17
1
6
7
21
19 Px
C
1 Py
18 20
SHUTTLE BLOCK MAIN CONTROL VALVE

3309S4EL02
1 Lamp 10 P3 pressure sensor 20 Travel pressure sensor

2 Fuel sender 12 EPPR Pressure sensor 21 Attach pressure sensor
3 Fuel filler pump 13 Start relay 22 Solenoid valve
4 Beacon lamp 14 Heater relay 23 Pump EPPR valve
5 Battery 15 Alternator 24 Boom priority EPPR valve
6 Battery relay 16 Travel alarm buzzer 25 Rear view camera kit
7 Horn 17 Air cleaner switch 26 MCU(machine control unit)
8 P1 pressure sensor 18 Swing pressure sensor
9 P2 pressure sensor 19 Boom up pressure sensor
※ Cluster type 1 only : 10, 12, 18, 19
4-2
GROUP 2 ELECTRICAL CIRCUIT
CIRCUIT(1/2, CLUSTER TYPE 1)
AC
COMP RY
CS-74A
R/DRYER 5R 146 146 5R
CS-74
1
WASHER P/P
85
86
145 5W 143 5R
Pa
2
87a 87
30
POWER RY
M
CABIN LAMP RY 138 2WR
MASTER SW FUSE BOX
CN-22
CN-29
CAMERA
DO-5
CR-7
87a
CN-95
2
1
30
86
85
2
87
87a 87 85
1
MASTER SW
30 86
2
1
5W 145
87a 87 85
30 86
10
2
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
5W 144
1
CN-259
30A
10A
30A
30A
20A
10A
10A
10A
20A
20A
10A
10A
10A
20A
30A
30A
10A
20A
30A
30A
10A
20A
10A
20A
20A
20A
20A
20A
10A
20A
10A
0.8GrW
0.8GrW
CR-35
0.8V
0.8L
0.8L
0.8V
FUSIBLE LINK
0.8
0.8
0.8V
0.8
87a
2
1
4
5
6
3
30
86
85
87
87a
ROOM LAMP/CASSETTE
5R 143
FUEL CUT-OFF SOL

CR-9
30
CABIN LAMP(OPTION)
86
85
87
2
OPTION(BEACON)
AIR CON/HEATER
5R BATTERY
148A
148E
NO. 142
CN-11
149
150
DESTINATION
39E
149
13A
1
39A
SWITCH PANEL
0.8Gr
0.8WOr
0.8V
0.8G
60
13
0.8L
FUEL HEATER
129
CS-74B
2B
FUEL HEATER RY
SH
1 AC GND
2WR
AC& HEATER
1 CN-60
SAFETY SOL
CONVERTER
0.8B
TRAVEL SOL
WORK LAMP
START,STOP
0.8Gr
SOLENOIDE
HEAD LAMP
2W
MCU CONT.
60B
MCU_EPPR
60R
0.8R
FUEL PUMP
START KEY
CASSETTE
1
IG POWER
2
2 BLOWER SIG. FUEL HEATER
PRE-HEAT
CLUSTER
2
2R
2V
CLUSTER
FUEL P/P
2L 148
155A
OPTION
87a 87 85
3 AC 24V
30 86
138
3
WIPER
00
159
160
5B
SPARE
G3
WIPER
CIGAR
M
24
34
HORN
140
CN-36
140A
21
30
MCU
4 REVERSE FAN
CN-96
4 CR-1
2W
2W
3Y 147 12V X 2
5 AC CONTROLLER B+ 5 G23 1.2B
2
1
CR-46
0.8 150
CN-61
6 AC COMP
87a
6 141 1.2G
30
TO:STARTER "B" TERM.
86
85
87
7 AC CONDENSOR FAN
1
2
7
2Br
0.8GrW
1.2ROr
2B
0.8RW
1.2RW
0.8RW
10E
1.2R
0.8Y
0.8ROr
0.8Gr
1.2Or
1.2Gr
1.2Or
8 ILLUMINATION
1.2Br
1.2Br
2W
2W
8
2RW
0.8R
1.2R
3Y
1.2V
2.0Y
0.8V
1.2V
BATT RY
0.8L
0.8
0.8
2R
2Y
2L
2L
0.8V
2B
2Y
0.8L
G31
AIR-CON
2Br
133
147
2L
DO-3
24
25
78
23
130
140
131
124
148
134
104
132
126
12
79
86
32
26
26
17
39
50
87
18
16
20
47
141E 0.8G
6
5
2
87A
133
122
0.8B 4
87
G24 0.8B
G21
126
1
CN-5 1
0.8Y
1 CLUSTER_TX 1
0.8L 2
2 CLUSTER_RX 2
SH 3G CD-43
3 SHIELD 3 A
1.2ROr 2A
SUPPLY
PRESS
0.8B 4
4 CLUSTER_GND 4 SIG B
1.2L 1
0.8Gr 5
5 CLUSTER_IG 5 1.2BW 4A
P2
0.8RW 6 RETURN C
6 CLUSTER_BATT.24V 6 CD-44
CD-42
7 ECONO SW_COM 7 1.2ROr 2 80H 1.2ROr
PRESS
SUPPLY A A SUPPLY
8 ECONO SW_NO 8 1.2G 3 91 1.2LW
0.8BW 82 SIG B B SIG
9 9 1.2BW 4 1.2BW
P1
P_DUMP(SERVICE CONN.) 81H
0.8Br 7 RETURN C C RETURN
10 QUICK COUPLER SW_NO 10
0.8Br 7 A3
11 OVERLOAD SW_COM 11
0.8ROr 00
12 OVERLOAD SW_NO 12
0.8ROr 10A
13 ILLUMINATION 13 CD-18
0.8W 11
14 HOUR METER SIG. 14 1 1.2GrW
15 RS232 RX(SERVICE CONN.) 15
0.8G 74 Pa
0.8R 73
16 RS232 TX(SERVICE CONN.) 16
0.8B 3F ENG OIL PS
17 GND(SERVICE CONN) 17
0.8R 12
18 WIPER CONT_BATT.24V 18
0.8V 13
19 WIPER CONT_WASHER P/P DRIVE 19
20 CAN_Hi(SERVICE CONN) 20 CN-28
2 1.2VW
1
21 CAN_Lo(SERVICE CONN) 21
22 CAN SHIELD 22
23 CAMERA_2 23 AC COMP
0.8GrW 39
24 WIPER IG 24 CN-2
1.2ROr 104 46 0.8Y 1.2GrW 1
25 OPTION SW 25 1
1.2B 15
26 HEAT SEAT_GND 26 2 CN-79
1.2Gr 16 60 0.8V 1.2VW 2 3 2B
27 CIGAR LIGHTER_IG 27 3 G
1.2V 17 00 0.8 1.2 00 4 2W
28 DC-DC CONVERTER 24V 28 4 F
1.2Or 18 86E 0.8 1.2LW 5 5 1.2LW
29 SPARE SW_COM(IG) 29 5 H
1.2B 19A 00 0.8 1.2 00
30 GND 30 19 2B 6 FUEL CUT OFF SOL
1.2B 19E 00 0.8 1.2 00
31 GND 31 7
64 2W 2W 4
32 NC 32 8 CN-75
1.2Br 20 56 Or 1.2Or 6 6 1.2Or
33 BEACON SW_COM(IG) 33 9 2
1.2V 21A 21 2V 75 Br 1.2Br 7 7 1.2Br
34 CABIN LIGHT 34 10 1
0.8BOr 22 8 Y 1.2Y 8
35 START KEY SW_START 35 11 EPPR V/V
1.2W 23 9 L 1.2L 9
36 START KEY SW_COM 36 12
00 0.8 1.2 00 CD-17
37 CAMERA_3 37 13 8 1.2Y
0.8V 21E 68 2B 2B 3 2 m
38 CABIN LIGHT 38 14 9 1.2L rp
00 0.8 1.2 00 1
39 REVERSE FAN AUTO 39 15
TACHO SENSOR
40 REVERSE FAN MANUAL 40
0.8BrW 77 ENG.HARNESS REAR
41 RS232 RX2(GPS) 41
0.8GrW 76
42 RS232 TX2(GPS) 42 CR-23 CN-45
43 NC 43 CN-3
68A 0.8B 1.2 10 10 B M
44 NC 44
64E 0.8
1
1.2 11 11 Gr
1 M
45 NC 45 2 2
0.8Y 25 66 0.8W 1.2 12
46 CASSETTE RADIO_BATT.24V 46 3
0.8V 26 67 0.8Y 1.2 13 START RY B+
47 CASSETTE RADIO_IG 47 4 FROM BATT.RY
0.8B 27 81A 0.8 1.2 14 STARTER
48 CASSETTE RADIO_GND 48 5
0.8BrW 28 43 0.8 1.2 15
49 SWITCH PANEL_HEAD LIGHT 49 6
0.8VW 29
50 SWITCH PANEL_WORK LIGHT 50 7
15 R
51 CAMERA GND 51
0.8 84
8 RS-1 CN-74
0.8 84 43 0.8 0.8 15 16
52 CAMERA SIG. 52 9 2 B+
0.8 84 43 0.8 0.8 15 3W/300 12A
53 CAMERA SHIELD 53 10 1 G
0.8 84 43 0.8 0.8 15 1 P
54 SWITCH PANEL_PREHEAT 54 11 12 1.2W 3~
0.8Gr 30 43 SH SH 15 2 L
55 SWITCH PANEL_CABIN LAMP 55 12
3 FI
U
0.8RW 32
56 SWITCH PANEL_TRAVEL ALARM 56 4 NC
0.8RW 32
57 SWITCH PANEL_IG 57 CR-24
0.8B 33 15R ALT.
58 SWITCH PANEL_GND 58 13 V
0.8WOr 34 CN-249
59 START SW_ACC 59 1
0.8B 24
0.8GW 35 15R
60 START SW_BR 60 0.8L 22
2
0.8Y 23
3 PRE-HEAT RY Pre-heater
0.8Gr 21
CN-8 4
1 NC 1 CAMERA
2 NC 2 CD-8
14 B
3 NC 3 ENG.HARNESS FRONT 15 G
1 C
4 NC 4 2
0.8 18
5 GND 5 WATER TEMP SENDOR
6 NC 6
0.8 18
7 ILLUMINATION 7
8 NC 8
9 NC 9
10 NC 10 CR-36
55 0.8BOr
1
11 NC 11 132A 0.8L 4 5 1
12 NC 2
12 132 0.8L
3
CN-7 4
1 NC 1 67 0.8Y 3 2
5
2 NC 2 PRE-HEAT RY
3 NC 3
0.8 18 CR-5
4 SEAT HEAT 4 131 2.0Y
30
0.8Or 18
5 BREAKER SW 5 22 0.8BOr
86
87a 87 85
0.8BW 40
6 BREAKER SW 6 64 2W
0.8B G42 87
7 HORN 7 123 0.8Br
0.8GrW 41 85
8 HORN 8 30 86
87a
9 BUTTON 2 9
ANTI-RESTART RY
10 BUTTON 2 10
11 BUTTON 1 11 CR-13
50 1.2Br
12 BUTTON 1 12 30
50A 0.8Br 87a 87 85
13 NC 13 86
0.8Gr 42 10 1.2ROr
14 ACCEL DIAL SUPPLY 14 87
0.8W 99 28 0.8BrW
15 ACCEL DIAL SIGNAL 15 85
0.8B 37 30 86
16 ACCEL DIAL GND 16 87a
RH CONSOL HEAD LAMP RY

CN-4 CL-4
1 G22 1.2B
1 NC 2
10 1.2ROr
2 NC 2 1
3 NC 3 HEAD LAMP
4 NC 4 CR-62 CL-3
0.8GrW 00 1.2B
5 POWER MAX SW 5 G30 0.8Br
1
G22
2
0.8B 81R 5 1
6 POWER MAX SW 6 40 0.8BW 4 10 1.2ROr
0.8GrW 48 2 1
7 ONE TOUCH DECEL 7 18 0.8Or
3 HEAD LAMP
0.8B 81R
8 ONE TOUCH DECEL 8 4
9 BUTTON 2 9 136 0.8Br
5 3 2 CN-12 CL-5
G11 2B B 2 2 B
10 BUTTON 2 10 BREAKER RY 128 2RG
2
V V
1
1 1
11 BUTTON 1 11 1 2
12 BUTTON 1 12 CR-4 WORK LAMP
2A B
13 NC 13 130 2RW
30 1
1.2B G41 V
14 SAFETY SW COM 14 130A 0.8RW
86
87a 87 85 1A
2
15 SAFETY SW NC 15 128 2RG
87 CL-6
1.2G 49
16 SAFETY SW NO 16 29 0.8VW
85
LH CONSOL 87a 30 86
CN-68 WORK LAMP RY

1.2G 49
1
1.2V 134
2 CR-2
41 0.8GrW
SAFETY SOL 1
124A 0.8V 4 5 1
CN-140 2
B 152 124 0.8V
1 3
0.8Br 7 CN-25
2 4 G12 0.8B
127 0.8G 3 2 2
QUICK COUPLER 5 127 0.8G
1
HORN RY
CD-10 HORN
1.2B 81S G13 0.8B
2
Pa 1.2YOr 83 127 0.8G
1
AIR CLEANER SW CN-20
CD-2
0.8B 81R
1
0.8 100
2
FUEL LEVEL
CD-1
0.8B 81
C 1
0.8 101
2
HYD TEMP
G32
47E
120
121
158
136
80
98
81
0.8ROr
0.8GW
0.8LOr
0.8BW
0.8BW
0.8Or
0.8Br
0.8Br
0.8B
CN-15
10
11
12
2
6
7
8
9
1
4
3
5
2B 3
42A
37A
63
54
36
2B
1
2
3
4
5
6
7
4
5
101
118
118
118
118
118
118
118
118
118
123
118
118
118
118
118
118
118
82
76
76
76
77
55
00
90
00
91
00
00
0.8Gr
80E
81E
80A
81A
80A
81A
81H
80A
9
81J
3E
78
79
80
81
42
37
54
53
11
51
73
74
94
96
80
90
91
1
3
W
8
G
V
0.8GrW
0.8GrW
0.8GrW
0.8OrW
0.8BrW
1.2ROr
0.8BOr
1.2LOr
1.2RW
0.8LW
0.8Gr
0.8W
CN-76
0.8G
1.2R
0.8R
1.2B
0.8B
0.8V
1.2B
0.8Y
0.8V
0.8Y
0.8L
0.8L
0.8WOr
1.2
SH
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8OrW
0.8ROr
0.8ROr
0.8BOr
0.8ROr
0.8ROr
0.8ROr
6
5
4
3
2
0.8BW
0.8BW
1
0.8BW
0.8BW
0.8BW
0.8LW
0.8V
105
104
47H
47G
106
70
47A
118
CN-51
CN-52
6
7
119
SIG
47
M+
P+
NC
M-
P-
10
11
12
13
SPEED SENSOR+(HMC) 14
15
16
17
18
19
20
21
22
RS485+(TX)-CLUSTER 23
24
25
TRAVEL ALARM SELECT SIG 26
27
28
AIR CLEANER SW(NO) 29
30
31
32
RS485-(RX)-CLUSTER 33
34
35
36
37
38
39
40
10
11
12
13
14
15
16
BOOM PRIORITY EPPR- 17
18
PUMP POWER EPPR- 19
20
21
22
23
24
25
FUEL LEVEL SENSOR 26
27
GOV. POTENTIO SIG. 28
29
30
31
PUMP EPPR2 SENSOR 32
ATT PILOT PRESSURE 33
34
35
36
WORK PRESS SENSOR(A) 37
38
39
40
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
PUMP POWER EPPR+ 9
CD-24
CD-32
CD-31
CD-6
CD-7
0.8V
0.8ROr
0.8Or
1
0.8RW
5
0.8BW
0.8BW
0.8GOr
0.8BrW
RETURN C
RETURN C
A
B
A
B
RETURN C
2
RETURN C
RETURN C
A
B
A
B
A
B
0.8Rw
0.8W
0.8Or
0.8Or
0.8Or
M
TRAVEL PRESS SENSOR(A)

BOOM PRIORITY EPPR+
ARM IN_OUT BUCKET IN PRESS
0.8
0.8
PRE-HEAT SELECT SIG
WATER TEMP SENDOR
BOOM UP PRESS SENSOR

TRAVEL SPEED SOL
HYD. TEMP SENDER

ATT_CONFLUX SOL.
0.8LOr
0.8GW
ONE TOUCH DECEL
P1 PRESS SENSOR
P2 PRESS SENSOR
POWER BOOST SW
SWING PRESS SENSOR

RS232C1_RX-HRDT
ENGINE OIL FILTER

SUPPLY
SUPPLY
RS232C1_TX-HRDT
SUPPLY
SUPPLY
SUPPLY
0.8Or
0.8Or
0.8Or
0.8Br
ENG PRE-HEAT RY
FUEL WARMER RY
RS232C2_RX-RCM
0.8Br
6
BATT POWER_24V
RS232C2_TX-RCM
3
ATT_ SAFETY SOL
CN-81
ANTI RESTART RY
0.8B
POWER MAX SOL
POWER_24V OUT
TACHO SENSOR+
PROGRAM DUMP
ARM REGEN SOL
ATT_PRESS SOL.
TACHO SENSOR-
TRAVEL BUZZER
POWER IG EPPR
POWER_5V OUT
ACCEL DIAL SIG
CN-242
CN-133
CN-70
2
1
CD-69
CN-88
SIG
SIG
GOV. MOTOR
SIG
OVERLOAD SIG
SIG
SIG
CN-135
1
1
2
1
2
1
GND_RETURN
2
G/A MOTOR(+)
RETURN C
1
A
B
2
ENG STOP RY
HOUR METER
G/A MOTOR(-)
BLOWER SIG.
CN-149
CN-236
CN-237
CAN_SHIELD
CN-66
1
1
ATT. EPPR+
1
ENG OIL PS
1
coolent level
2
ATT. EPPR-
GND_MAIN
BOOM WORK
EPPR GND
ALT. LEVEL
SUPPLY
SWING OVER
POWER IG
TRAVEL
LOAD UP
CAN1 Lo
GND_5V
CAN1 Hi
SIG
ATT BOOM ARM TRAVEL POWER
FLOW TRAVEL BZ PRIORITY REGEN HIGH MAX ATT. ATT.
nc
nc
nc
nc
nc
nc
nc
nc
nc
nc
nc
nc
nc
ATT. PS ATT. BREAKER SOL.

PRESS SAFETY CONFLUX
SOL.
MCU
3309S4EL03
4-3
·ELECTRICAL
ELECTRICAL CIRCUIT (2/2, CLUSTER TYPE 1)
Service Tool DC/DC CONVERTER CIGARLIGHT RELAY

OVERLOAD SW
RS232 P_DUMP
12V SOCKET INTAKE M/ACT MODE(D/FOOT) MODE(VENT) BLOWER
24V
HOUR METER TEMP M/ACT
12
12
10
3
4
9
ECONO SWITCH
12V
2 7 2 7
RS232_RX
RS232_TX
h
1 4 1 4 BLOWER
M M
12
M M
12
CAN2_Lo
3
3
1
3 7 7
10
CAN2_Hi
3
4
9
CAN_Lo
CAN_Hi
CN-139
CN-48
GND
12V
IG 24V
24V
5 5
CL-2
M
CN-138
GND
4
2
5
6
7
5
6
7
5
6
7
1
2
3
4
5
6
7
1
2
3
4
1
2
3
4
1
2
3
4
CS-67
3
2
1
11
1
1
CS-50
2
8
C
A
B
1
1
2
1
4
2
3
10
11
12
CN-21
9
4
8
1
2
3
6
7
11
1 12
1
CS-52
1.2Gr
7
8
2
1.2B
0.8W
ROr
0.8B
0.8Y
3 1 WIPER CUT
G
00
D
0.8G
B
C
E
A
10
F
11
12
1.2Or
R 10
9
3
8
1
2
3
6
7
24M 1.2B
1.2Or
1.2V
24L 1.2B
2
0.8VOr
9 0.8Br
0.8Or
0.8Or
0.8Br
Gr 12 4
24Q
0.8V
24R 0.8B
12B
5 3
35E
CS-53
24V
21
13
R 4A 5
60
1 0.8BW
0.8Or
4
27F 0.8Br
60
22
0.8G
0.8G
0.8B
24T 0.8B
6 0.8G
6 0.8G
6 0.8G
6 0.8G
2 0.8G
3 0.8R
5 0.8V
4 0.8B
4 G 8 6
61
11
27
10
61
5 23F 0.8Or 3
9 7
L 7 HARNESS AIR-CON
B
6 M 2 6 23F 0.8Or 9
62
62
CN-126
Or
8
7
2A
4 CN-11 NO. DESTINATION
10
8
9
8
7
6
5
4
9
3
2
1
11
WIPER MOTOR 10 1 1 GND
10
9A 0.8Br
11
2 2 BLOWER SIG
0.8BW
24S 0.8B 11 12 3 3 FUSE(IG)
0.8G
0.8G
0.8R
0.8V
0.8B
12
4 4 REVERSE FAN
CN-141 QUICK COUPLING SW
G 8 5 5 FUSE(Battery)
59
73
72
71
70
69
FEED BACK 1
W 1 6 6 DPS(COMPRESSOR)
MOTOR DRIVE SIG 2 CN-17 CN-113
3
L 9 00 0.8B 7 7 CONDENSOR FAN
MOTOR DRIVE- 1
1
4
R 10 1 W 0.8W 48 00 0.8G
8 8 ILLUMINATION
MOTOR DRIVE+ 2
2
B 2 2 B 1.2B 24B
GND 5 3
GrW 3 3 GrW 0.8ROr 65 BUZZER
VCC 6 4
R 4 4 R 0.8R 14
CONTINUE 24V 7 5
V 5 5 V 0.8V 15
WASHER P/P 8 6
L 6 6 L 0.8L 49
WASHER SIG. 9 7
CN-56
Br 7 7 Br 0.8Br 50
INT. SIG 10 8 6 0.8RW RW
Or 11 1 BATT.24V
WIPER CUT SW 11 WR
2 SIG_3
N.C 12 81 1.2B B
Gr 12 3 GND
FEED BACK 13 WIPER MOTOR HARNESS 1 0.8Y Y
4 TX
WIPER MOTOR CONT. 5 0.8Gr Gr
5 IG 24V
WL
6 SIG_2
10
11
12
13
14
15
16
17
18
10
11
12
13
14
1 0.8W
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
W
7 CAMERA SIG
2 0.8L L
TEMP MOTOR ACT(+)
DUCT SENSOR(GND)
8 RX
TEMP MOTOR ACT(-)
DPS(COMPRESSOR)
MODE M/ACT(FOOT)
BLOWER RELAY(Lo)
INLET MOTOR(REC)
INLET MOTOR(FRE)
0
0
0
0
MODE M/ACT(PBR)
MODE M/ACT(DEF)
AMBIENT SENSOR
TEMP M/ACT(PBR)
CONDENSOR FAN
CLUSTER
MOTOR ACT(REF)
1
2
DUCT SENSOR(+)
W/TEMP SENSOR
MODE M/ACT(M+)
POWER TR BASE
MODE M/ACT(M-)
FET(FEED BACK)
INCAR SENSOR
REVERSE FAN
ILLUMINATION
ILLUMINATION
> > >
BATTERY(+)
CS-82 CN-5
FET(GATE)
POWER IG
0.8B 20E 1 0.8Y POWER TR AMBIENT INCAR W/TEMP
12 1 1 MCU_RX
12 11 26A SENSOR SENSOR SENSOR
IG 24V
0.8LW 2 0.8L
11 2 2 MCU_TX DUCT
GND
3 SH SENSOR
NC
NC
NC
10 3 3 MCU_GND
10 4 0.8B
8 9 4 4 GND
4 1.2ROr 19A 5 0.8Gr AC&HEATER CONTROLLER(auto)
8 5 5 FUSE
9 6 0.8RW
7 7 6 6 FUSE
3 7 0.8B CS-1 CN-24
6 7 7 NC Gr 11 0.8G 2
8 0.8Or 2
5 8 8 NC NO. DESTINATION
1.2LW 26 59 0.8BW 1
0.8V 3 CN-10
4 9 9 P_DUMP(MCU) 1
9 0.8Br CL-1 1 NC
3 10 10 QUICK COUPLING SOL DOOR S.W Gr 11 SPEAKER RH
10 0.8V 3 2 2 NC
2 11 11 OVERLOAD PS 0.8Y 1 1 0.8Y
FUSE
12 1 11 0.8VOr 2 3 3
1 12 12 MCU_OVERLOAD 0.8B 6 2 0.8G
CASSETTE_RH-
12 0.8ROr 1 4 4
SPARE 13 13 HEAD LAMP RY CN-23 ROOM LAMP MG651032 3 0.8V
5 5 CASSETTE_RH+
13 0.8W
14 14 MCU_HOURMETER 0.8Y 4 4 0.8Y
69 0.8G 2 6 6 CASSETTE_LH-
15 15 RS232_RX(MCU) 0.8L 5 5 0.8L
70 0.8R 1 7 7 CASSETTE_LH+
16 16 RS232_TX(MCU) 6 2.0B
71 0.8B SPEAKER LH 8 8 GND
17 17 GND 7 2.0B
14 0.8R CL-7 9 9 GND
18 18 FUSE 1.2BrW 8 8 1.2BrW
15 0.8V 10 10 BEACON SW
19 19 WASHER P/P M 1.2B 6A 9 2.0V
72 0.8V 11 11 CABIN LIGHT RY
20 20 CAN_Hi 10 2.0V
73 0.8G BEACON LAMP 12 12 CABIN LIGHT RY
21 21 CAN_Lo
74 SH
22 22 Shieeld CL-8 CL-9 HARNESS CABIN
2.0V 9 10 2.0V
23 23 NC 2 2
65 0.8ROr 1.2B 6B 7 1.2B
24 24 WIPER FUSE 1 1
19 1.2ROr
25 25 FUSE CABIN LIGHT
20 1.2B
26 26 GND
21 1.25Gr ACCEL DIAL LED
27 27 FUSE CS-83
CN-279
22 1.2V 0.8B 19G
CS-23 28 28 FUSE 12 CS-26A
1
2
0.8B 24J 23 1.2Or 12 11 0.8Or 18A 5E 0.8BW
12 29 29 FUSE 11 2
12 11 0.8BrW 58A 24A 1.2B 4E 0.8G
11 30 30 GND 10 1
24E 1.2B 10 0.8G 15
0.8ROr
10 24 2B 31 31 GND 8 9
BREAKER
0.8B
10 4 0.8V 16
8 9 32 32 NC 8
4 1.2Br 27E 27 1.2Br 9 0.8BrW 17
8 33 33 FUSE 7 7 CN-156
9 28 2V 28A 1.2V 3 19 1.2B
32
19F
7 7 34 34 CABIN LAMP RY 6 2
3 29 1.2BOr 31 1.2ROr
6 35 35 ANTI RESTART RY 5 1
30 1.2W 0.8Or 18
5 36 36 FUSE 4 AIR SEAT
1.2BrW 58 0.8Gr 20
4 37 37 NC 3 NO. DESTINATION
28E 0.8V CN-8
3 38 38 CABIN LAMP RY 2 15 0.8G
NC
12 1 1 1
2 39 39 joy stick 1 16 0.8V
12 1 2 2 FUSE
1 40 40 NC CRAB SW 17 0.8BrW
75 0.8BrW 3 3 CRAB COM
BEACON LAMP SW 41 41 RS232 RX2 CS-99
18 0.8Or
76 0.8GrW 4 4 NC
CN-125A 42 42 RS232 TX2 0.8B 19A 19 1.2B
0.8W 30E
12 5 5 NC
43 43 NC 12 11 0.8GW 21A 20 0.8Gr
BATTERY POWER 1 11 6 6 CRAB SIG_MCU
1.2R 47A 44 44 NC 32 0.8ROr
KEY "IG" 2 10 7 7 ILLUMINATION
45 45 NC 10 22 0.8L
NC 3 35 0.8Y 8 9 8 8 NC
0.8BrW 75 46 46 FUSE 4 0.8L 22 23 0.8VW
RX232(1)-TX 4 36 0.8V 8 9 9 NC
0.8B 71A 47 47 FUSE 9 0.8L 22A 24 0.8R
RX232(1)-GND 5 37 0.8B 7 7 10 10 NC
48 48 GND 3 25 0.8LW
RX232(2)-RX 6 38 0.8BrW 6 11 11 NC
RX232(2)-TX 7 49 49 HEAD LAMP RY 26 0.8RW
12
39 0.8VW 5 12 NC
RX232(2)-GND 8 50 50 WORK LAMP RY 4
0.8GW 21
0.8GrW 76 00 0.8B
51 51 CAMERA GND 0.8RW 26
RX232(1)-RX 9 00 0.8W 3
NC 10 00 SH
52 52 CAMERA SIG 2
HARNESS RH,CONSOL
53 53 CAMERA SHIELD 12 1
MAIN GND 11 40 0.8WOr 1
0.8B 24H 54 54 PRE-HEAT
MAIN GND 12 41 0.8Gr AIR-COMP
RMS 55 55 CABIN LAMP RY
42 0.8YW
56 MCU_TRAVEL ALARM SW
CS-100
56 0.8B 19E
CN-10 43 0.8RW 12 CN-7 NO. DESTINATION
57 57 FUSE 12 11 0.8V 29
1 NC 1 44 0.8B 11 1 1 NC
58 58 GND 0.8V 29
2 NC 2 45 0.8WOr 10 2 2 NC
0.8Y 35A 59 59 POWER RY 10 0.8VW 23
3 ROOM LAMP 24V 3 46 0.8GW 6 9 3 3 NC
0.8G 51 60 60 BATT. RY 4 31 1.2ROr
4 SPEAKER RH- 4 8 4 4 NC
0.8V 53 9 0.8G 4 0.8G
5 SPEAKER RH+ 5 5 7 1
4
5 5 BREAKER SW
0.8Y 52 3 0.8R 24 BREAK
B 0.8BW 5 0.8BW
6 SPEAKER LH- 6 5
0.8L 55
6
0.8R
2 6 6 BREAKER RY
24A CS-26 0.8B 6 6 0.8B
7 SPEAKER LH+ 7 5 1 7 7 GND
1.2B 24F 24 2B CS-2 0.8Br 30 HORN
R 0.8Grw 7 7 0.8Grw
8 GND 30 1.2W
H 0 I
8 4 2 8 8 HORN RY
1.2B 24G 1 0.8LW 25 CS-5 0.8L 8
9 GND 46 0.8GW 8 0.8L
9 3 9 9 NC
0, I
1.2BrW 58 2 2 L 0.8L 9
10 BEACON LAMP 47 1.2R 9 0.8L
10 2 10 10 NC
3
H
1.2V 28F 28 2V 4 12 1 0.8Br 30 0.8Gr 10 10 0.8Gr
11 CABIN LIGHT 11 1 11 11 NC
4
BR ACC
1.2V 28G 1
B
2 1 Gr 0.8Gr 11 11 0.8Gr
12 CABIN LIGHT 12 3 SPARE 12 12 NC
5
29 1.2BOr
HARNESS CABIN 6 CN-142 13 13 NC
0.8Gr 12 12 0.8Gr
14 14 MCU_5V
ST C
5 + A
6 0.8W 13 13 0.8W
S B 15 15 MCU_ACCEL SIG.
START KEY SW 0.8B 14 14 0.8B
- C 16 16 MCU_SUPPLY GND
CN-116 ACCEL DIAL
12 NC
44 0.8B
11 GND
43 0.8RW
10 POWER 24V CS-33
9 NC 6 6
42 0.8YW
5 5
41 0.8Gr
8 TRAVEL ALARM HARNESS LH,CONSOL
7 CABIN LIGHT OUT 4 4
40 0.8WOr
6 PRE-HEAT 3 3
49 0.8L
5 WASHER SIG 2 2 CN-4 NO. DESTINATION
48 0.8W
4 WIPER MOTOR DRIVE 1 1 1 1 NC
50 0.8Br
3 INT. SIG EM'CY STOP SW 2 2 NC
39 0.8VW
38 0.8BrW
2 WORK LIGHT OUT 3 3 NC
36E
36E
1 HEAD LIGHT OUT 4 4 NC

12F
25
68
18
63
31
0.8Y 4 4 0.8Y
51
17
35
12
53
16
37
37E
SWITCH PANEL 1 5 5 MCU_POWER MAX

36
power
max B 0.8B 5 5 0.8B
6 6 MCU_SIG.GND
0.5ROr
2
0.8ROr
0.5BW
0.8BOr
0.5GY
0.5YL
0.5Lg
0.5LY
0.8Or
cs-29 0.8Grw 6 6 0.8Grw

0.5V
0.5V
0.8G
0.8V
0.5B
0.8Y
0.8V
0.8B
decel
1 7 7 MCU_DECEL
R 0.8B 7 7 0.8B
2 8 8 MCU_SIG.GND
cs-19 0.8L 8 8 0.8L
CN-246
CN-27A
CN-27
L
9 9 NC
10
11
12
13
14
15
16
2
1
4
5
8
2
4
5
8
10
9
3
6
3
0.8L 9 0.8L
1
2
3
4
5
6
7
9
8
10 10 NC
0.8Gr 10 10 0.8Gr
11 11 NC
REMOCON GND
SPK FRT RH+
SPK FRT LH+

SPK FRT RH-
1 Gr
SPK FRT LH-
0.8Gr 11 11 0.8Gr
REMOCON+
12 12 NC
USB(GND)
TEL MUTE
BACK UP+
USB GND
AUX GND
AUX GND
USB(D+)
CS-4 13 13 NC
USB(D-)
ANT 12V
USB D+
AUX S1
USB 5V
AUX S2
USB D-
0.8B 12 12 0.8B
AUX R
AUX L
B C
USB+
A 14 14 GND
GND
0.8V 13 13
ACC
0.8V
ILL+
NC
NC
NC
NC
ILL-
B 15 15 NC
NC
NC
NC
HARNESS RH SIDE 0.8G 14 14 0.8G

A C 16 16 SAFETY SOL
USB&SOCKET ASS'Y REMOTE ASS'Y CASSETTE RADIO SAFETY SW
3309S4EL04
4-4
■ ELECTRICAL CIRCUIT (1/2, CLUSTER TYPE 2)
AC
COMP RY
CS-74A
R/DRYER 5R 146 146 5R
CS-74
1
87a 87 85
WASHER P/P
30 86
145 5W 143 5R
2
Pa
POWER RY
M
138 2WR
MASTER SW CABIN LAMP RY
CN-22
CN-29
FUSE BOX
DO-5
CR-7
87a
CN-95
2
1
30
2
86
85
1
87
87a 87 85
30 86
2
MASTER SW
1
5W 145
87a 87 85
2
30 86
10
1
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
5W 144
1
30A
10A
30A
30A
20A
10A
10A
10A
20A
10A
10A
10A
30A
20A
30A
30A
10A
20A
30A
30A
10A
20A
10A
20A
20A
20A
20A
20A
10A
20A
10A
0.8GrW
0.8GrW
CR-35
0.8V
0.8L
0.8L
0.8V
FUSIBLE LINK
0.8
0.8
0.8V
0.8
87a
30
86
85
87
CR-9
ROOM LAMP/CASSETTE
87a
5R 143
CABIN LAMP(OPTION)
30
86
85
87
2
OPTION(BEACON)
AIR CON/HEATER
5R
148A
148E
142 BATTERY
NO. CN-11
149
150
DESTINATION 1
39E
149
13A
39A
0.8WOr
60
SWITCH PANEL
13
FUEL CUT OFF

2B
CS-74B
129
FUEL HEATER
1 AC GND FUEL HEATER RY
2WR
1 CN-60
0.8B
AC& HEATER
SAFETY SOL
CONVERTER
TRAVEL SOL
WORK LAMP
START,STOP
0.8Gr
2W
60B
SOLENOIDE
60R
HEAD LAMP
MCU CONT.
0.8R
FUEL PUMP
START KEY
1
2
CASSETTE
FUEL HEATER
IG POWER
2 BLOWER SIG. 2
PRE-HEAT
2R
2V
CLUSTER
FUEL P/P
2L 148
OPTION
3 AC 24V
87a 87 85
138
30 86
3
SPARE
G3
WIPER
SPARE
WIPER
SPARE
M
CIGAR
24
34
HORN
CN-36
140
140A
4 REVERSE FAN
21
30
MCU
CN-96
4 CR-1
2W
12V X 2
2W
3Y 147
5 AC CONTROLLER B+ 5 G23 1.2B
2
1
CR-46
0.8 150
CN-61
6 AC COMP
87a
6 141 1.2G
30
TO:STARTER "B" TERM.
86
85
87
7 AC CONDENSOR FAN
1
2
7
2Br
0.8GrW
1.2ROr
2B
0.8RW
1.2RW
0.8RW
1.2R
0.8Y
0.8ROr 10E
0.8Gr
1.2Or
1.2Gr
1.2Or
8 ILLUMINATION
1.2Br
1.2Br
2W
2W
8
2RW
0.8R
1.2R
3Y
1.2V
2.0Y
0.8V
1.2V
0.8L
BATT RY
0.8
2.0
2R
2Y
2L
2L
0.8V
2B
2Y
0.8L
G31
AIR-CON
2Br
133
147
2L
DO-3
24
25
78
23
130
140
131
124
148
134
104
132
126
12
79
86
32
26
26
17
39
50
87
18
16
20
47
141E 0.8G
6
5
2
87A
133
122
0.8B 4
87
G24 0.8B
G21
1
126
CN-5 0.8Y 1
1 CLUSTER_TX 1
0.8L 2
2 CLUSTER_RX 2
SH 3G
3 SHIELD 3
0.8B 4
4 CLUSTER_GND 4
0.8Gr 5
5 CLUSTER_IG 5
0.8RW 6
6 NC 6
7 NC 7 CD-43
1.2ROr 2A
8 NC 8 SUPPLY A
PRESS
0.8BW 82 1.2L 1
9 P_DUMP(SERVICE CONN.) 9 SIG B
0.8Br 7 1.2BW 4A
P2
10 QUICK COUPLER SW_NO 10 RETURN C CN-1
0.8Br 7 1 0.8L 85
11 OVERLOAD SW_COM 11 CD-42 1
0.8ROr 00 1.2ROr 2 2 1.2ROr 80P
12 OVERLOAD SW_NO
PRESS
12 SUPPLY A 2
0.8ROr 10A 1.2G 3 3 0.8G 84
13 ILLUMINATION 13 SIG B 3 CD-18
P1
0.8W 11 1.2BW 4 4 0.8BW 81P
14 HOUR METER SIG. 14 RETURN C 4 1
0.8G 74 4 0.8BW 81P
1.2GrW Pa
15 RS232 RX(SERVICE CONN.) 15 5
0.8R 73 CD-44
16 RS232 TX(SERVICE CONN.) 16 1.2ROr 2 6
PRESS
0.8B 3F SUPPLY A
17 GND(SERVICE CONN) 17 1.2G 3 ENG OIL PS
0.8R 12 SIG B
P3
18 WIPER CONT_BATT.24V 18 1.2BW 4
0.8V 13 RETURN C
19 WIPER CONT_WASHER P/P DRIVE 19
20 CAN_Hi(SERVICE CONN) CN-28
20 2 1.2VW
1
21 CAN_Lo(SERVICE CONN) 21
22 CAN SHIELD 22
23 23 AC COMP
0.8GrW 39
24 WIPER IG 24 CN-2
1.2ROr 104 46 0.8Y 1.2GrW 1
25 OPTION SW 25 1
1.2B 15
26 GND 26 2 CN-79
1.2Gr 16 60 0.8V 1.2VW 2 3 2B
27 CIGAR LIGHTER_IG 27 3 G
1.2V 17 00 0.8 1.2 00 4 2W
28 DC-DC CONVERTER 24V 28 4 F
1.2Or 18 86E 0.8 1.2LW 5 5 1.2LW
29 SPARE SW_COM(IG) 29 5 H
1.2B 19A 00 0.8
30 GND 30 19 2B 6 FUEL CUT OFF SOL
1.2B 19E 00 0.8
31 GND 31 7
64 2W 2W 4
32 NC 32 8 CN-75
1.2Br 20 56 Or 1.2Or 6 6 1.2Or
33 BEACON SW_COM(IG) 33 9 2
1.2V 21A 21 2V 75 Br 1.2Br 7 7 1.2Br
34 CABIN LIGHT 34 10 1
0.8BOr 22 8 Y 1.2Y 8
35 START KEY SW_START 35 11 EPPR V/V
1.2W 23 9 L 1.2L 9
36 START KEY SW_COM 36 12
00 0.8
13
1.2 00 CD-17
37 NC 37 68 2B 2B 3 8 1.2Y
0.8V 21E 2 m
38 CABIN LIGHT 38 14 9 1.2L rp
00 0.8 1.2 00 1
39 NC 39 15
TACHO SENSOR
40 NC 40
41 NC 41 ENG.HARNESS REAR ENG.HARNESS
42 NC 42 CR-23 CN-45
43 NC 43 CN-3
68A 0.8B 1.2 10 10 B M
44 NC 44
64E 0.8
1
1.2 11 11 Gr
1 M
45 NC 45 2 2
0.8Y 25 66 0.8W 1.2 12
46 CASSETTE RADIO_BATT.24V 46 3
0.8V 26 67 0.8Y 1.2 13 START RY B+
47 CASSETTE RADIO_IG 47 4 FROM BATT.RY
0.8B 27 81A 0.8 1.2 14 STARTER
48 CASSETTE RADIO_GND 48 5
0.8BrW 28 43 0.8 1.2 15
49 SWITCH PANEL_HEAD LIGHT 49 6
0.8VW 29 0.8
50 SWITCH PANEL_WORK LIGHT 50 7
15 R
51 NC 51 8 RS-1 CN-74
16
52 NC 52 9 2 B+
0.8 84
3W/300 12A
53 BREAKER SW 53 10 1 G
0.8 84 1 P
54 SWITCH PANEL_PREHEAT 54 11 12 1.2W 3~
0.8Gr 30 2 L
55 SWITCH PANEL_CABIN LAMP 55 12
3 FI U
0.8RW 32
56 SWITCH PANEL_TRAVEL ALARM 56 4 NC
0.8RW 32
57 SWITCH PANEL_IG 57 CR-24
0.8B 33 15R ALT.
58 SWITCH PANEL_GND 58 13 V
0.8WOr 34
59 START SW_ACC 59
0.8GW 35 15R
60 START SW_BR 60
PRE-HEAT RY Pre-heater
CN-8
1 NC 1
2 NC 2 14
CD-8
B
3 NC 3 1 C
15 G
4 NC 4 2
0.8 18
5 GND 5 WATER TEMP SENDOR
6 NC 6
0.8 18
7 ILLUMINATION 7
8 NC 8
9 NC 9
10 NC 10 CR-36
55 0.8BOr
1
11 NC 11 132A 0.8L 4 5 1
2
12 NC 12 132 0.8L
3
CN-7 4
1 NC 1 67 0.8Y 3 2
5
2 NC 2 PRE-HEAT RY
3 NC 3
0.8 18 CR-5
4 SEAT HEAT 4 131 2Y
30
0.8Or 18
5 BREAKER SW 5 22 0.8BOr
86
87a 87 85
0.8BW 40
6 BREAKER SW 6 64 2W
0.8B G42 87
7 HORN 7 123 0.8Br
0.8GrW 41 85
8 HORN 8 30 86
87a
9 BUTTON 2 9
ANTI-RESTART RY
10 BUTTON 2 10
11 BUTTON 1 11 CR-13
50 1.2Br
12 BUTTON 1 12 30
50A 0.8Br 87a 87 85
13 NC 13 86
0.8Gr 42 10 1.2ROr
14 ACCEL DIAL SUPPLY 14 87
0.8W 99 28 0.8BrW
15 ACCEL DIAL SIGNAL 15 85
0.8B 37 30 86
16 ACCEL DIAL GND 16 87a
RH CONSOL HEAD LAMP RY

CN-4 CL-4
G22 1.2B
1 NC 1 2
2 NC 2 10 1.2ROr
1
3 NC 3 HEAD LAMP
4 NC 4 CR-62 CL-3
0.8GrW 00
5 POWER MAX SW 5 G30 0.8Br
1
G22 1.2B
2
0.8B 81R
6 POWER MAX SW 6 40 0.8BW
2
4 5 1 10 1.2ROr
1
0.8GrW 48
7 ONE TOUCH DECEL 7 18 0.8Or
3 HEAD LAMP
0.8B 81R
8 ONE TOUCH DECEL 8 4
9 BUTTON 2 9 136 0.8Br
5 3 2 CN-12
2
CL-5
G11 2B B 2 B
10 BUTTON 2 10 BREAKER RY
2 1
128 2RG V 1 1 V
11 BUTTON 1 11 1 2
12 BUTTON 1 12 CR-4 WORK LAMP
2A B
13 NC 13 130 2RW
30 1
1.2B G41
14 SAFETY SW COM 14 130A 0.8RW
86
87a 87 85 1A V
2
15 SAFETY SW NC 15 128 2RG
87 CL-6
1.2G 49
16 SAFETY SW NO 16 29 0.8VW
85
LH CONSOL 87a 30 86
CN-68 WORK LAMP RY

1.2G 49
1
1.2V 134
2 CR-2
41 0.8GrW
SAFETY SOL 1
124A 0.8V 4 5 1
CN-140 2
B 152 124 0.8V
1 3
0.8Br 7 CN-25
2 4 G12 0.8B
127 0.8G 3 2 2
QUICK COUPLER 5 127 0.8G
1
HORN RY
CD-10 HORN
1.2B 81S G13 0.8B
2
Pa 1.2YOr 83 127 0.8G
1
CN-20
0.8Br
AIR CLEANER SW
0.8B
CD-2
CN-66
0.8B 81R
1
1
2
0.8 100
2
FUEL LEVEL
CD-1 BREAKER SOL.
0.8B 81
C 1
0.8 101
2
HYD TEMP
3 2B
27
81H
80A
81J
81J
2B
117
80
90
91
80
90
8A
26
34
OR/W 28
GY/W 30
14
47
16
38
39
40
31
45
36
13
G/OR 11
29
25
B/OR 33
65
67
12
32
55
63
62
62
50
57
37
54
64
51
44
46
W/OR 61
66
23
68
69
71
72
73
48
42A
BR/OR
3
37A
G/W
R/W
Y/W
B/W
Y/W
Y/W
B/W
V/W
63
54
36
L/W
0.8OrW
OR
OR
0.8OrW
GY
GY
BR
BR
BR
0.8ROr
0.8ROr
0.8ROr
0.8BW
0.8BW
0.8BW
0.8LW
W
W
W
G
G
R
R
Y
B
Y
B
L
47G
105
104
0.8Gr
47A
70
118
119
CN-51
CN-50
47
W
G
V
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25
26
27
28
29
30
31
32
33
34
35
36
10
11
12
TRAVEL SPEED SOL. 13
14
15
16
17
18
19
20
ENGINE OIL FILTER 21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
1
2
3
4
5
6
7
GND(PRES.SENSOR) 8
9
1
2
3
4
5
6
7
8
9
CD-6
CD-7
CD-31
0.8V
0.8Or
0.8RW
0.8GOr
0.8BrW
CN-76
C
C
SUPPLY A
RETURN B
SUPPLY A
RETURN B
C
0.8W
SUPPLY A
RETURN B
0.8Or
0.8Or
6
5
4
3
2
1
HYD TEMP SENDOR

24V(PRES.SENSOR)
TACHO SENSOR(+)
BOOM PRIORITY SOL

WATER TEMP SENDOR
TRAVEL ALARM SW
TACHO SENSOR(-)
POWER MAX SOL.
ANTI-RESTART RY
PUMP PROLIX SW
AIR CLEANER SW
ENG PREHEATER
PROGRAM DUMP
CN-81
WATER LEVEL SW
TRAVEL BUZZER
POWER MAX SW
GND (POT&DIAL)
MAX FLOW SOL.

ACCEL DIAL SIG
BATTERY 24V(+)
OVERLOAD SIG
GND (SENSOR)
CN-133
CN-70
SIG
P1 PRESS SIG.
P2 PRESS SIG.
P3 PRESS SIG.
2
1
O/T DECEL SW
PUMP EPPR(+)
CN-88
5V (POT&DIAL)
M+
P+
NC
PUMP EPPR(-)
SIG
SIG
PRE-HEAT SW
M-
ACCEL ACT(+)
HOUR-METER
HOUR-METER
FUEL HEATER
SIG
P-
1
2
1
2
ACCEL ACT(-)
1
WORKING PS
2
RS232 (GND)
TRAVEL PS
ENG OIL PS
GND (MAIN)
1
5
SERIAL-RX
SERIAL-TX
ALT LEVEL
POWER IG
2
TRAVEL WORK
RS232 (+)
M
OVERLOAD PS
RS232 (-)
POT-SIG
6
GND
GOV. MOTOR BOOM TRAVEL POWER

NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
TRAVEL BZ PRIORITY HIGH MAX
MCU
3309S4EL05
4-5
·ELECTRICAL
ELECTRICAL CIRCUIT (2/2, CLUSTER TYPE 2)
Service Tool DC/DC CONVERTER CIGARLIGHT

OVERLOAD SW RELAY
HOUR METER INTAKE M/ACT TEMP M/ACT MODE(D/FOOT) MODE(VENT) BLOWER
RS232 P_DUMP
12V SOCKET
24V
12
12
10
3
4
9
ECONO SWITCH
12V
2 7 2 7
h
RS232_RX
4 4 BLOWER
RS232_TX
1 1
12
M M M M
12
3
3
1
3 7 7
10
CAN2_Lo
3
CAN2_Hi
9
CN-48
CAN_Lo
CAN_Hi
GND
CN-139
12V
24V
5 5
IG 24V
CL-2
CN-138
M
4
2
GND
5
6
7
5
6
7
5
6
7
1
2
3
4
5
6
7
1
2
3
4
1
2
3
4
1
2
3
4
CS-67
3
2
1
11
1
1
CS-50
2
8
C
A
B
1
1
2
1
4
2
3
10
11
12
CN-21
9
4
8
1
2
3
6
7
11
1 12
CS-52
1
1.2Gr
7
8
2
1.2B
0.8W
ROr
0.8B
0.8Y
3 1 WIPER CUT
G
00
D
0.8G
B
C
E
A
F
J
10
11
1.2Or
12
R 10 3
24M 1.2B
4
8
1
2
3
6
7
1.2Or
1.2V
24L 1.2B
2
0.8VOr
9 0.8Br
0.8Or
0.8Or
0.8Br
Gr 12 4
24Q
0.8V
24R 0.8B
12B
5 3
35E
24V
21
CS-53
13
R 4A 5
60
0.8BW
0.8Or
4
27F 0.8Br
60
22
0.8G
0.8G
0.8B
24T 0.8B
0.8G
0.8G
0.8G
0.8G
0.8G
0.8R
0.8V
0.8B
4 G 8 6
61
11
27
10
61
5 23F 0.8Or 3
9
L 7 7 HARNESS AIR-CON
B
6 2 6 9
6
6
6
6
5
4
3
2
1
M 23F 0.8Or
62
62
CN-126
Or
8
7
2A
4 CN-11 NO. DESTINATION
10
8
9
8
7
6
5
4
9
3
2
1
11
WIPER MOTOR 10 1 1 GND
10
9A 0.8Br 2 2 BLOWER SIG
11
0.8BW
24S 0.8B 11 12 3 3 FUSE(IG)
0.8G
0.8G
0.8R
0.8V
0.8B
12
4 4 REVERSE FAN
CN-141 QUICK COUPLING SW
G 8 5 5 FUSE(Battery)
59
73
72
71
70
69
FEED BACK 1
W 1
CN-17 6 6 DPS(COMPRESSOR)
MOTOR DRIVE SIG 2 CN-113
L 9 00 0.8B 7 7 CONDENSOR FAN
MOTOR DRIVE- 3 1
R 10 1 W 0.8W 48 1 8 8 ILLUMINATION
MOTOR DRIVE+ 4 2 00 0.8G
B 2 2 B 1.2B 24B 2
GND 5 3
GrW 3 3 GrW 0.8ROr 65
VCC 6 4 BUZZER
R 4 4 R 0.8R 14
CONTINUE 24V 7 5
V 5 5 V 0.8V 15
WASHER P/P 8 6
L 6 6 L 0.8L 49
WASHER SIG. 9 7
Br 7 7 Br 0.8Br 50
INT. SIG 10 8
Or 11
WIPER CUT SW 11
N.C 12
Gr 12 WIPER MOTOR HARNESS
FEED BACK 13
WIPER MOTOR CONT. CN-56

17 BR RR
1 POWER IG(24V)
10
11
12
13
14
15
16
17
18
10
11
12
13
14
B
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
18
2 GND
19 Y
TEMP MOTOR ACT(+)
DUCT SENSOR(GND)
3 RX
TEMP MOTOR ACT(-)
DPS(COMPRESSOR)
MODE M/ACT(FOOT)
BLOWER RELAY(Lo)
INLET MOTOR(REC)
INLET MOTOR(FRE)
20 L
0
0
0
0
MODE M/ACT(PBR)
MODE M/ACT(DEF)
AMBIENT SENSOR
TEMP M/ACT(PBR)
CONDENSOR FAN
4 TX
1
2
MOTOR ACT(REF)
DUCT SENSOR(+)
W/TEMP SENSOR
MODE M/ACT(M+)
POWER TR BASE
MODE M/ACT(M-)
FET(FEED BACK)
INCAR SENSOR
CLUSTER
REVERSE FAN
ILLUMINATION
ILLUMINATION
> > >
BATTERY(+)
CS-82 CN-5
FET(GATE)
POWER IG
0.8B 20E 1 0.8Y POWER TR AMBIENT INCAR W/TEMP
12 1 1 MCU_RX SENSOR SENSOR SENSOR
12 11 0.8LW 26A 2
IG 24V
0.8L DUCT
11 2 2 MCU_TX
GND
3 SH SENSOR
NC
NC
NC
10 3 3 MCU_GND
10 4 0.8B
8 9 4 4 GND
4 1.2ROr 19A 5 0.8Gr AC&HEATER CONTROLLER(auto)
8 5 5 FUSE
9
7 7 6 6 NC
3 7 0.8B CS-1 CN-24
6 7 7 NC Gr 11 0.8G 2
8 0.8Or
5 8 8 NC 2
1.2LW 26 59 0.8BW 0.8V 3 CN-10 NO. DESTINATION
4 9 9 P_DUMP(MCU) 1
9 0.8Br CL-1 1 1 NC
3 10 10 QUICK COUPLING SOL DOOR S.W Gr 11 SPEAKER RH
10 0.8V 3 2 2 NC
2 11 11 OVERLOAD PS 0.8Y 1 1 0.8Y
FUSE
12 1 11 0.8VOr 2 3 3
1 12 12 MCU_OVERLOAD 0.8B 6 2 0.8G
CASSETTE_RH-
12 0.8ROr 1 4 4
SPARE 13 13 HEAD LAMP RY CN-23 MG651032 3 0.8V
13 0.8W ROOM LAMP 5 5 CASSETTE_RH+
14 14 MCU_HOURMETER 0.8Y 4 4 0.8Y
69 0.8G 2 6 6 CASSETTE_LH-
15 15 RS232_RX(MCU) 0.8L 5 5 0.8L
70 0.8R 1 7 7 CASSETTE_LH+
16 16 RS232_TX(MCU) 6 2.0B
71 0.8B SPEAKER LH 8 8 GND
17 17 GND 7 2.0B
14 0.8R CL-7 9 9 GND
18 18 FUSE 1.2BrW 8 8 1.2BrW
15 0.8V 10 10 BEACON SW
19 19 WASHER P/P M 1.2B 6A 9 2.0V
72 0.8V 11 11 CABIN LIGHT RY
20 20 CAN_Hi 10 2.0V
73 0.8G BEACON LAMP 12 12 CABIN LIGHT RY
21 21 CAN_Lo
74 SH
22 22 Shieeld CL-8
2.0V 9 10 2.0V
CL-9 HARNESS CABIN
23 23 NC 2 2
65 0.8ROr 1.2B 6B 7 1.2B
24 24 WIPER FUSE 1 1
19 1.2ROr CABIN LIGHT
25 25 FUSE
26 26 GND
21 1.25Gr ACCEL DIAL LED
27 27 FUSE CS-83
CN-279
22 1.2V 0.8B 19G
CS-23 28 28 FUSE 12 CS-26A
1
2
0.8B 24J 23 1.2Or 12 11 0.8Or 18A 5E 0.8BW
12 29 29 FUSE 11 2
12 11 0.8BrW 58A 24A 1.2B 4E 0.8G
11 30 30 GND 10 1
24E 1.2B 10 0.8G 15
0.8ROr
10 24 2B 31 31 GND 8 9
0.8B
10 4 0.8V 16 BREAKER
8 9 32 32 NC 8
4 1.2Br 27E 27 1.2Br 9 0.8BrW 17
8 33 33 FUSE 7 7 CN-156
9 28 2V 28A 1.2V 3 19 1.2B
32
19F
7 7 34 34 CABIN LAMP RY 6 2
3 29 1.2BOr 31 1.2ROr
6 35 35 ANTI RESTART RY 5 1
30 1.2W 0.8Or 18
5 36 36 FUSE 4 AIR SEAT
1.2BrW 58 0.8Gr 20
4 37 37 NC 3
CN-8 NO. DESTINATION
28E 0.8V
3 38 38 CABIN LAMP RY 2 15 0.8G
12 1 1 1 NC
2 39 39 NC 1 16 0.8V
12 1 2 2 FUSE
1 40 40 NC SPARE 17 0.8BrW
3 3 CRAB COM
BEACON LAMP SW 41 41 NC 18 0.8Or
CS-99 4 4 NC
42 42 NC 0.8B 19A 19 1.2B
CS-27 12 5 5 NC
0.8B 24J 43 43 NC 12 11 0.8GW 21A 20 0.8Gr
12 11 6 6 CRAB SIG_MCU
12 11 0.8BrW 58A 44 44 NC 32 0.8ROr
11 10 7 7 ILLUMINATION
45 45 NC 10 22 0.8L
10 35 0.8Y 8 9 8 8 NC
10 46 46 FUSE 4 0.8L 22 23 0.8VW
8 9 36 0.8V 8 9 9 DPF REGEN
4 0.8 27E 47 47 FUSE 9 0.8L 22A 24 0.8R
8 37 0.8B 7 7 10 10 DPF COM
9 48 48 GND 3 25 0.8LW
7 7 38 0.8BrW 6 11 11 DPF INHIBIT
3 49 49 HEAD LAMP RY 26 0.8RW
6 39 0.8VW 5 12 12 AIR COMP RY
50 50 WORK LAMP RY 0.8GW 21
5 4
0.8 58 51 51 NC 0.8RW 26
4
52 52 NC
3 HARNESS RH,CONSOL
3 40 0.8 2
12 1
2
53 53 BREAKER SW(JOYSTICK) 1
12 1 40 0.8WOr
1
54 54 PRE-HEAT SPARE
41 0.8Gr
55 55 CABIN LAMP RY
BREAKER SW 42 0.8YW CS-100
56 56 MCU_TRAVEL ALARM SW
CN-10 43 0.8RW 1 CN-7 NO. DESTINATION
57 57 FUSE
1 NC 1 44 0.8B 2 1 1 NC
58 58 GND
2 NC 2 45 0.8WOr 3 2 2 NC
0
0.8Y 35A 59 59 POWER RY 0.8VW 23
3 ROOM LAMP 24V 3 46 0.8GW 4 3 3 NC
60 BATT. RY
0,1
0.8G 51 60 31 1.2ROr
4 SPEAKER RH- 4 5 4 4 FUSE
0.8V 53 0.8R 24 0.8G 4 0.8G
5 SPEAKER RH+ 5 4 R 6 1
4
5 5 BREAKER SW
0.8Y 52 BREAK
B 0.8BW 5 5 0.8BW
6 SPEAKER LH- 6 6 7 2 6 6 BREAKER RY
0.8L 55 0.8R 24A CS-26 0.8B 6 6 0.8B
7 SPEAKER LH+ 7 8 1 7 7 GND
1.2B 24F 24 2B CS-2 HORN
R 0.8Grw 7 7 0.8Grw
8 GND 30 1.2W
H0 I
8 10 I 9 2 8 8 HORN RY
1.2B 24G 1 0.8LW 25 CS-5 0.8L 8 8 0.8L
9 GND 9 46 0.8GW 8 10 9 9 NC
0, I
1.2BrW 58 2 2 L 0.8L 9 9 0.8L
10 BEACON LAMP 10 47 1.2R 11 10 10 NC
3 4
H
1.2V 28F 28 2V 12 11 0.8Br 30 0.8Gr 10 10 0.8Gr
11 CABIN LIGHT 11 12 11 11 NC
4
BR ACC
1.2V 28G 1 1 Gr
B
2 0.8Gr 11 11 0.8Gr
12 CABIN LIGHT 12 3 SPARE 12 12 NC
5
29 1.2BOr AIR COMP RY
HARNESS CABIN 6 CN-142 13 13
0.8Gr 12 12 0.8Gr
+ A 14 14 MCU_5V
ST C
5
6 0.8W 13 13 0.8W
S B 15 15 MCU_ACCEL SIG.
0.8B 14 14 0.8B
START KEY SW - C 16 16 MCU_SUPPLY GND
CN-116 ACCEL DIAL
12 NC
44 0.8B
11 GND
43 0.8RW
10 POWER 24V CS-33
9 NC 6 6
42 0.8YW
8 TRAVEL ALARM 5 5
41 0.8Gr
7 CABIN LIGHT OUT 4 4 HARNESS LH,CONSOL
40 0.8WOr
6 PRE-HEAT 3 3
49 0.8L
5 WASHER SIG 2 2 CN-4 NO. DESTINATION
48 0.8W
4 WIPER MOTOR DRIVE 1 1 1 1 NC
50 0.8Br
3 INT. SIG EM'CY STOP SW 2 2 NC
39 0.8VW
38 0.8BrW
2 WORK LIGHT OUT 3 3 NC
36E
36E
1 HEAD LIGHT OUT 4 4 NC

12F
25
68
18
63
31
0.8Y 4 4 0.8Y
51
17
35
12
53
16
37
37E
SWITCH PANEL 1 5 5 MCU_POWER MAX

36
power
max B 0.8B 5 5 0.8B
6 6 MCU_SIG.GND
0.5ROr
2
0.8ROr
0.8BOr
0.5BW
0.5GY
0.5YL
0.5Lg
0.5LY
0.8Or
cs-29 0.8Grw 6 6 0.8Grw

0.5V
0.5V
0.8G
0.8V
0.5B
0.8Y
0.8V
0.8B
decel
1 7 7 MCU_DECEL
R 0.8B 7 7 0.8B
2 8 8 MCU_SIG.GND
cs-19 0.8L 8 8 0.8L
CN-246
CN-27A
CN-27
L
9 9 NC
10
11
12
13
14
15
16
2
1
4
5
8
2
4
5
9
10
3
6
3
0.8L 9 0.8L
1
2
3
4
5
6
7
9
8
10 10 NC
0.8Gr 10 10 0.8Gr
11 11 NC
REMOCON GND
SPK FRT RH+
SPK FRT LH+

SPK FRT RH-
1 Gr
SPK FRT LH-
0.8Gr 11 11 0.8Gr
REMOCON+
12 12 NC
USB(GND)
TEL MUTE
BACK UP+
USB GND
AUX GND
AUX GND
USB(D+)
CS-4 13 13 NC
ANT 12V
USB(D-)
USB D+
AUX S1
USB 5V
AUX S2
USB D-
0.8B 12 12 0.8B
AUX R
AUX L
B C
USB+
A 14 14 GND
GND
0.8V 13 13
ACC
0.8V
ILL+
NC
NC
NC
NC
ILL-
B 15 15 NC
NC
NC
NC
0.8G 14 14 0.8G
HARNESS RH SIDE A C 16 16 SAFETY SOL
USB&SOCKET ASS'Y REMOTE ASS'Y CASSETTE RADIO SAFETY SW
3309S4EL06
4-6
MEMORANDUM
HYUNDAI HEAVY INDUSTRIES CO., LTD

CONSTRUCTION EQUIPMENT DIV.
4-7
1. POWER CIRCUIT (CLUSTER TYPE 1)
The negative terminal of battery is grounded to the machine chassis through master switch.
When the start switch is in the OFF position, the current flows from the positive battery terminal as
shown below.
1) OPERATING FLOW
Battery Battery relay Fusible link [CN-60] Master switch [CS-74]
Fuse box [No.1] Power relay [CR-35 (30)]
Fuse box [No.2] I/conn [CN-5 (46)] I/conn [CN -10 (3)] Room lamp [CL-1 (2)]
Door switch [CS-1]
Cassette radio [CN-27 (8)]
Hour meter [CN-48 (1)]
Fuse box [No.3] MCU controller [CN-51 (1)]
Fuse box [No.4] l/conn [CN-5 (36)] Start switch [CS-2 (1)]
RMS [CN-125A(1)]
Fuse box [No.5] l/conn [CN-11 (5)] AC & Heater controller
Blower relay
Fuse box [No.6] I/conn [CN - 5 (18)] I/conn [CN -17 (5)] Wiper motor controller
[CN-141 (7)]
Wiper motor [CN-21 (4)]
Fuse box [No.7] I/conn [CN - 5 (6)] I/conn [CN -56 (1)] Cluster
※ I/conn : Intermediate connector
2) CHECK POINT
Engine Start switch Check point Voltage
① - GND (battery 1EA) 10~12.5V

② - GND (battery 2EA) 20~25V
OFF OFF
③ - GND (battery 2EA) 20~25V
④ - GND (fusible link) 20~25V
※ GND : Ground
4-8
CN-141
MASTER SW
R
CONTINUE 24V 7
2
1
WIPER MOTOR CONTROLLER
CS-74B
CN-17
CN-21 1 2W CR-35
2W
2W
1 2 30
3 0.8WOr 87a 87 85
2 86
3
2WR
3 87
5 4 0.8B
R R 85
4 5
30 86
POWER RY
4 87a
5 6
0.8Gr
0.8RW
6 M 2 6 7 CN-5
8 1 CN-36
8
7
6
5
4
3
2
1
2 30A
CN-56
WIPER MOTOR 2W IG POWER
3 1
L
Gr
Y
B
W
0.8Y ROOM LAMP/CASSETTE 10A
WL
WR
RW
4 2
CN-125A 0.8Gr 1.2R MCU 30A
0.8W 5 3
BATTERT POWER 1 0.8RW 2W START KEY 30A
1.2R
TX
RX
6 4
SIG_2
GND
KEY "IG" 2
SIG_3
IG 24V
3Y 20A
5R
AIR CON/HEATER
BATT.24V
7 5
RMS 0.8R 10A
CAMERA SIG
WIPER
CLUSTER
8 6
6 0.8RW CLUSTER 10A
5
9
C ST
CS-2 7
17 0.8Gr CLUSTER 10A
6 0.8R 0.8R 8
18 MCU CONT. 20A
3 5 9
138
2 19 MCU_EPPR 20A
B
1
ACC BR
4 10
1.2R 20 10A
SWITCH PANEL
H
4 3
21 11
10A
0, I
POWER CIRCUIT (CLUSTER TYPE 1)
2 CASSETTE
1.2W 22 12
START KEY SW
1 FUEL CUT OFF-SOL. 10A
I 0 H
23 13
CONVERTER 20A
24 14
WORK LAMP 30A
31 15
CABIN LAMP(OPTION) 30A
32 16
33 WIPER 10A
17
4-9
34 HEAD LAMP 20A
18
35 FUEL HEATER 30A
CN-27 1.2W 1.2W 19
36 START,STOP 30A
ACC 1 20
37 HORN 10A
145 5W
ILL- 2 38 21
AC& HEATER 20A
NC 3 CN-48 39 22
SAFETY SOL 10A
SPK FRT RH- 4 3 42 23
h 2 OPTION 20A
SPK FRT LH- 5 0.8Y 43 24
1 SOLENOIDE 20A
TEL MUTE 6 44 25
20A
HOUR METER
ANT 12V 7 45 CIGAR
0.8Y 0.8Y 0.8Y 26
OPTION(BEACON) 20A
BACK UP+ 8 46 27
ILL+ 9 47 TRAVEL SOL 20A
28
CR-1
3
48 PRE-HEAT 10A
0.8Y
NC 10
29
57 20A
BATT RY
SPK FRT RH+ 11 FUEL P/P
CASSETTE RADIO
30
5
4
1
9
8
7
6
3
58
12
11
10
REMOCON+ 12 SPARE 10A
0.8WOr 0.8WOr
CN-10
59 31
FUSE BOX
REMOCON GND 13
60
SPK FRT LH+ 14
2
NC 15 CS-74A
60R
Gr
5R
Gr
GND 16
0.8Y
1
1
2
1
2
5R
CN-60
CN-95
2
CS-74
1
2
FUSIBLE LINK
CL-1
CN-11
MASTER SW
(12VX2)
CS-1
5R
1
5R
5W
BATTERY
5W
DOOR SW
BATTERY(+) 3 2
ROOM LAMP
4
ILLUMINATION 4 3
60B
W/TEMP SENSOR 10
1
4
AC & HEATER CONTROLLER(AUTO) 3Y
5
6
1 2 1 7
8
3309S4EL07
2
3
4 4 CN-51
3 1.2
BLOWER RY
BATT POWER 24V 1
MCU
■ POWER CIRCUIT (CLUSTER TYPE 2)
The negative terminal of battery is grounded to the machine chassis through master switch.
When the start switch is in the OFF position, the current flows from the positive battery terminal as
shown below.
1) OPERATING FLOW
Battery Battery relay Fusible link [CN-60] Master switch [CS-74]
Fuse box [No.1] Power relay [CR-35 (30)]
Fuse box [No.2] I/conn [CN-5 (46)] I/conn [CN -10 (3)] Room lamp [CL-1 (2)]
Door switch [CS-1]
Cassette radio [CN-27 (8)]
Hour meter [CN-48 (1)]
Fuse box [No.3] MCU controller [CN-50 (7)]
Fuse box [No.4] l/conn [CN-5 (36)] Start switch [CS-2 (1)]
Fuse box [No.5] l/conn [CN-11 (5)] AC & Heater controller
Blower relay
Fuse box [No.6] I/conn [CN - 5 (18)] I/conn [CN -17 (5)] Wiper motor controller
[CN-141 (7)]
Wiper motor [CN-21 (4)]
※ I/conn : Intermediate connector
2) CHECK POINT
① - GND (battery 1EA) 10~12.5V

② - GND (battery 2EA) 20~25V
OFF OFF
③ - GND (battery 2EA) 20~25V
④ - GND (fusible link) 20~25V
※ GND : Ground
4-10
CN-141
MASTER SW
R
CONTINUE 24V 7
2
1
CS-74B
CN-17
CN-21 1 2W CR-35
2W
2W
1 2 30
3 0.8WOr 87a 87 85
2 86
3
2WR
3 87
5 4 0.8B
R R 85
4 5
30 86
POWER RY
4 87a
5 6
BR
6 M 2 6 7 CN-5
8 1 CN-36
4
3
2
1
WIPER MOTOR 2 2W IG POWER 30A
CN-56
3 1
0.8Y ROOM LAMP/CASSETTE 10A
RR
4 2
0.8Gr 1.2R MCU 30A
5 3
2W START KEY 30A
6 4
3Y 20A
5R
AIR CON/HEATER
TX
RX
7 5
GND
0.8R WIPER 10A
8 6
POWER IG(24V)
CLUSTER
9 SPARE 10A
0.8W 0.8W 7
14 0.8Gr CLUSTER 10A
8
6 15 MCU CONT. 20A
5 9
C ST
CS-2
138
16 FUEL CUT OFF 10A

6 10
17 SWITCH PANEL 10A
5 0.8R 0.8R 11
3 18
2 CASSETTE 10A
B
1
POWER CIRCUIT (CLUSTER TYPE 2)
ACC BR
4 19 12
1.2R SPARE 30A
H
4 3 20 13
CONVERTER 20A
0, I
2 21 14
1.2W 30A
WORK LAMP
START KEY SW
1 31 15
I 0 H
32 16
33 WIPER 10A
17
34 HEAD LAMP 20A
4-11
18
35 FUEL HEATER 30A
CN-27 1.2W 1.2W 19
36 START,STOP 30A
ACC 1 20
37 HORN 10A
145 5W
ILL- 2 38 21
AC& HEATER 20A
NC 3 CN-48 39 22
0.8W SAFETY SOL 10A
SPK FRT RH- 4 3 42 23
h 2 OPTION 20A
SPK FRT LH- 5 0.8Y 43 24
1 SOLENOIDE 20A
TEL MUTE 6 44 25
20A
HOUR METER
ANT 12V 7 45 CIGAR
0.8Y 0.8Y 0.8Y 26
OPTION(BEACON) 20A
BACK UP+ 8 46 27
ILL+ 9 47 TRAVEL SOL 20A
28
CR-1
3
NC 10 48 PRE-HEAT 10A
0.8Y
29
57 20A
BATT RY
SPK FRT RH+ 11 FUEL P/P
CASSETTE RADIO
30
5
4
1
9
8
7
6
3
58
12
11
10
REMOCON+ 12 SPARE 10A
0.8WOr 0.8WOr
CN-10
59 31
FUSE BOX
REMOCON GND 13
60
SPK FRT LH+ 14
2
NC 15 CS-74A
60R
Gr
5R
Gr
GND 16
0.8Y
1
1
2
1
2
5R
CN-60
CN-95
2
CS-74
1
2
FUSIBLE LINK
CL-1
CN-11
MASTER SW
(12VX2)
CS-1
5R
1
5R
5W
BATTERY
5W
DOOR SW
BATTERY(+) 3 2
ROOM LAMP
4
ILLUMINATION 4 3
60B
W/TEMP SENSOR 10
1
4
AC & HEATER CONTROLLER(AUTO) 3Y
5
6
1 2 1 7
2 8
3309S4EL08
3
4 4 CN-50
3 GY
BLOWER RY
BATT POWER 24V(+) 7
W/OR
HOUR METER 22
MCU
2. STARTING CIRCUIT (CLUSTER TYPE 1)
1) OPERATING FLOW
Battery(+) terminal Battery relay [CR-1] Fusible link [CN-60] Master switch [CS-74]
Fuse box [No.4] Master switch [CS-74B] I/conn [CN-5(36)] Start switch [CS-2(1)]
(1) When start key switch is in ON position
Start switch ON [CS-2 (2)] I/conn [CN-5 (60)] Battery relay [CR-1]
Battery relay operating (all power is supplied with the electric component)
Start switch ON [CS-2 (3)] I/conn [CN-5 (59)] Power relay [CR-35 (86) → (87)]
Fuse box [No.10]
GPS [CN-125A (2)]
(2) When start key switch is in START position
Start switch START [CS-2 (6)] I/conn [CN-5 (35)] Anti-restart relay [CR-5 (86) → (87)]
l/conn [CN-3 (2)] Start relay [CR-23]
l/conn [CN-2 (8)] Fuel cut off solenoid
2) CHECK POINT
① - GND (battery)
② - GND (start key)
③ - GND (battery relay M4)
OPERATING START ④ - GND (starter B+) 20~25V
⑤ - GND (starter M)
⑥ - GND (start relay)
⑦ - GND (battery relay M8)
※ GND : Ground
4-12
CN-5
1
MASTER SW
2
2
1
3
CS-74B
4
5 2W CR-35
2W
2W
30
6 0.8WOr 87a 87 85
86
7 2WR
87
8 0.8B
CN-125A 85
0.8W 9 30 86
POWER RY
BATTERT POWER 1 87a
1.2R 17
KEY "IG" 2
18
RMS
19 CN-36
20 2W IG POWER 30A
1
21 ROOM LAMP/CASSETTE 10A
22 2
MCU 30A
23 3
6 2W START KEY 30A
5
ST C
CS-2 1.2BOr 24 4
AIR CON/HEATER 20A
6 31 5
5 WIPER 10A
3 32 6
2
B
10A
BR ACC
1 CLUSTER
5R
4 33
1.2R 7
10A
H
4 3 34 CLUSTER
0.8GW 1.2BOr 0.8BOr 8
20A
0, I
2 35 MCU CONT.
1.2W 1.2W 1.2W 9
138
1 36 20A
START KEY SW
MCU_EPPR
H 0 I
10
37 SWITCH PANEL 10A
11
38 CASSETTE 10A
2
39 12
0.8 FUEL CUT OFF-SOL. 10A
57 CN-51 0.8V
13
CONVERTER 20A
ANTI-RESTART RY 20
STARTING CIRCUIT (CLUSTER TYPE 1)
58 14
0.8WOr 0.8WOr WORK LAMP 30A
59 MCU 15
0.8GW 0.8GW CABIN LAMP(OPTION) 30A
60 16
CN-52 WIPER 10A
ALT LEVEL 27 17
HEAD LAMP 20A
MCU 18
4-13
FUEL HEATER 30A
19
2Y
2W
2Y START,STOP 30A
0.8Br
0.8BOr
20
5W
HORN 10A
21
20A
87
AC& HEATER
145
85
86
30
87a
22
CR-5
0.8
2B
10A
0.8B
0.8
2W
SAFETY SOL
0.8W
23
OPTION 20A
30
87a 87
24
20A
86
3
3
2
2
9
8
7
6
5
4
9
8
7
6
5
4
1
1
85
12
11
10
15
14
13
12
11
10
SOLENOIDE
25
CN-3
CN-2
3
CIGAR 20A
1.2B
1.2G
26
0.8B
0.8G
ANTI-RESTART RY
OPTION(BEACON) 20A
2B
2W
27
1.2LW
20A
2
TRAVEL SOL
1
28
CR-1
DO-3
B
PRE-HEAT 10A
Gr
6
29
DIODE
20A
7
BATT RY
FUEL P/P
30
SPARE 10A
3W/300
1
2
31
FUSE BOX
2
1
RS-1
1
CS-74A
60R
CR-23
5R
1
START RY
1
2
1
2
5R
CN-60
CN-95
2
CS-74
5R
5R
5W
5W
MASTER SW
FUSIBLE LINK
(12VX2)
4
BATTERY
60B
1.2W
B+
2B
2W
CN-45
15 R
1.2LW
4
3
2
1
F
M
H
G
L
P
FI
STARTER
3309S4EL09
B+
NC
ALT
CN-79
CN-74
3
~
G
U
FUEL CUT OFF SOL
■ STARTING CIRCUIT (CLUSTER TYPE 2)
1) OPERATING FLOW
Battery(+) terminal Battery relay [CR-1] Fusible link [CN-60] Master switch [CS-74]
Fuse box [No.4] Master switch [CS-74B] I/conn [CN-5(36)] Start switch [CS-2(1)]
(1) When start key switch is in ON position
Start switch ON [CS-2 (2)] I/conn [CN-5 (60)] Battery relay [CR-1]
Battery relay operating (all power is supplied with the electric component)
Start switch ON [CS-2 (3)] I/conn [CN-5 (59)] Power relay [CR-35 (86) → (87)]
Fuse box [No.10]
(2) When start key switch is in START position
Start switch START [CS-2 (6)] I/conn [CN-5 (35)] Anti-restart relay [CR-5 (86) → (87)]
I/conn [CN-3 (2)] Start relay [CR-23]
l/conn [CN-2 (8)] Fuel cut off solenoid
2) CHECK POINT
① - GND (battery)
② - GND (start key)
③ - GND (battery relay M4)
OPERATING START ④ - GND (starter B+) 20~25V
⑤ - GND (starter M)
⑥ - GND (start relay)
⑦ - GND (battery relay M8)
※ GND : Ground
4-14
CN-5
1
MASTER SW
2
2
1
3
CS-74B
4
5 2W CR-35
2W
2W
30
6 0.8WOr 87a 87 85
86
7 2WR
87
8 0.8B
85
9 30 86
POWER RY
87a
17
18
19 CN-36
20 2W IG POWER 30A
1
21 ROOM LAMP/CASSETTE 10A
22 2
MCU 30A
23 3
6 2W START KEY 30A
5
ST C
CS-2 1.2BOr 24 4
AIR CON/HEATER 20A
6 31 5
5 WIPER 10A
3 32 6
2
B
10A
BR ACC
1 SPARE
5R
4 33
1.2R 7
10A
H
4 3 34 CLUSTER
0.8GW 1.2BOr 0.8BOr 8
20A
0, I
2 35 MCU CONT.
1.2W 1.2W 1.2W 9
138
1 10A
START KEY SW
36 1.2R FUEL CUT OFF
H 0 I
10
37 SWITCH PANEL 10A
11
38 CASSETTE 10A
2
39 12
SPARE 30A
57 CN-50 V/W
13
CONVERTER 20A
ANTI-RESTART RY 11
STARTING CIRCUIT (CLUSTER TYPE 2)
58 14
0.8WOr 0.8WOr WORK LAMP 30A
59 MCU 15
0.8GW 0.8GW CABIN LAMP(OPTION) 30A
60 16
CN-51 WIPER 10A
W
ALT LEVEL 9 17
HEAD LAMP 20A
MCU 18
4-15
FUEL HEATER 30A
19
2Y
2W
2.0Y START,STOP 30A

0.8Br
0.8BOr
20
5W
HORN 10A
21
20A
87
AC& HEATER
145
85
86
30
87a
22
CR-5
0.8
2B
10A
0.8B
0.8
2W
SAFETY SOL
0.8W
23
OPTION 20A
30
87a 87
24
20A
86
3
3
2
2
9
8
7
6
5
4
9
8
7
6
5
4
1
1
85
12
11
10
15
14
13
12
11
10
SOLENOIDE
25
CN-3
CN-2
3
CIGAR 20A
1.2B
1.2G
26
0.8B
0.8G
ANTI-RESTART RY
OPTION(BEACON) 20A
2B
2W
27
1.2LW
20A
2
TRAVEL SOL
1
28
CR-1
DO-3
B
PRE-HEAT 10A
Gr
6
29
DIODE
20A
7
BATT RY
FUEL P/P
30
SPARE 10A
3W/300
1
2
31
FUSE BOX
2
1
RS-1
1
CS-74A
60R
CR-23
5R
1
START RY
1
2
1
2
5R
CN-60
CN-95
2
CS-74
5R
5R
5W
5W
MASTER SW
FUSIBLE LINK
(12VX2)
4
BATTERY
60B
1.2W
B+
2B
2W
CN-45
15 R
1.2LW
4
3
2
1
F
M
H
G
L
P
FI
STARTER
3309S4EL10
B+
NC
ALT
CN-79
CN-74
3
~
G
U
FUEL CUT OFF SOL
3. CHARGING CIRCUIT (CLUSTER TYPE 1)
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery relay
[CR-1].
The current also flows from alternator to each electrical component and controller through the fuse box.
1) OPERATING FLOW
(1) Warning flow
Alternator "I" terminal I/conn [CN-3 (3)] MCU alternator level [CN-52 (27)]
Cluster charging warning lamp(Via serial interface)
(2) Charging flow

Alternator "B+" terminal Battery relay(M8) Battery(+) terminal
Fusible link [CN-60] Master switch [CS-74]
Fuse box
2) CHECK POINT
① - GND (battery voltage)

② - GND (battery relay)
Run ON ③ - GND (alternator B+ terminal) 20~30V
④ - GND (alternator I terminal)
⑤ - GND (MCU)
※ GND : Ground
4-16
SH
0.8L
0.8Y
CN-51 CN-36
5
4
1
9
8
7
6
3
60
59
58
57
24
23
22
21
20
19
18
17
30A
0.8L
IG POWER
0.8Y
BATT POWER_24V 1
CN-5
1
POWER IG 2 ROOM LAMP/CASSETTE 10A
SH
2
8
7
6
5
4
3
2
1
POWER_24V OUT 3
0.8L
0.8Y
MCU 30A
CN-56
TACHO SENSOR+ 4 3
5 START KEY 30A
L
Gr
Y
B
W
WL
WR
RW
CAN1 Hi
4
21 20A
AIR CON/HEATER
nc 22 5
0.8L 10A
RS485+(TX)-CLUSTER 23 WIPER
6
TX
RX
RS232C1_TX-HRDT 24 10A
SIG_2
GND
CLUSTER
5R
SIG_3
IG 24V
RS232C2_TX-RCM 25 7
BATT.24V
CLUSTER 10A
CAMERA SIG
CLUSTER
8
ENG OIL PS 27 MCU CONT. 20A
coolent level 28 9
MCU_EPPR 20A
AIR CLEANER SW(NO) 29 10
BLOWER SIG. 30 SWITCH PANEL 10A
CAN1 Lo 31
11
CASSETTE 10A
nc 32 12
0.8Y
RS485-(RX)-CLUSTER 33 FUEL CUT-OFF SOL. 10A
13
CONVERTER 20A
ENGINE OIL FILTER 37 14
nc WORK LAMP 30A
38
15
nc 39 CABIN LAMP(OPTION) 30A
nc 40 16
WIPER 10A
17
CN-52 HEAD LAMP 20A
MCU
18
ARM REGEN SOL 1 30A
FUEL HEATER
POWER MAX SOL 2 19
CHARGING CIRCUIT (CLUSTER TYPE 1)
TRAVEL SPEED SOL 3 START,STOP 30A

20
5W
ATT_ SAFETY SOL 4 HORN 10A

ATT_PRESS SOL. 5 21
AC& HEATER 20A
145
ATT_CONFLUX SOL. 6 22
10A
0.8B
SAFETY SOL
0.8W
4-17
WATER TEMP SENDOR 25
23
OPTION 20A
FUEL LEVEL SENSOR 26 24
20A
3
2
9
8
7
6
5
4
1
ALT. LEVEL
12
11
10
27 SOLENOIDE
25
CN-3
GOV. POTENTIO SIG. 28 20A
CIGAR
1.2B
P1 PRESS SENSOR 29 26
0.8B
4
P2 PRESS SENSOR 30 OPTION(BEACON) 20A
27
20A
2
TRAVEL SOL
1
SWING PRESS SENSOR 36 28
CR-1
DO-3
B
PRE-HEAT 10A
Gr
WORK PRESS SENSOR(A) 37 29
DIODE
TRAVEL PRESS SENSOR(A) 20A
2
38 BATT RY FUEL P/P

OVERLOAD SIG 39 30
SPARE 10A
3W/300
1
2
nc 40 31
FUSE BOX
2
1
RS-1
1
CS-74A
60R
CR-23
5R
1
START RY
1
2
1
2
5R
CN-60
CN-95
2
CS-74
5R
5R
5W
5W
MASTER SW
FUSIBLE LINK
(12VX2)
BATTERY
60B
1.2W
3
B+
CN-45
15 R
4
3
2
1
M
L
P
FI
B+
NC
ALT
STARTER
CN-74
3
~
G
3309S4EL11
■ CHARGING CIRCUIT (CLUSTER TYPE 2)
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery relay
[CR-1].
The current also flows from alternator to each electrical component and controller through the fuse box.
1) OPERATING FLOW
(1) Warning flow
Alternator "I" terminal I/conn [CN-3 (3)] MCU alternator level [CN-51 (9)]
Cluster charging warning lamp(Via serial interface)
(2) Charging flow

Alternator "B+" terminal Battery relay(M8) Battery(+) terminal
Fusible link [CN-60] Master switch [CS-74]
Fuse box
2) CHECK POINT
① - GND (battery voltage)

② - GND (battery relay)
Run ON ③ - GND (alternator B+ terminal) 20~30V
④ - GND (alternator I terminal)
⑤ - GND (MCU)
※ GND : Ground
4-18
CN-51
SH
0.8L
0.8Y
WORKING PS 1
POWER MAX SW 2 CN-36
L
Y
5
4
1
9
8
7
6
3
TRAVEL ALARM SW 3
60
59
58
57
24
23
22
21
20
19
18
17
IG POWER 30A
CN-5
ENG OIL PS 4 1
NC 5
ROOM LAMP/CASSETTE 10A
SH
2
4
3
2
1
0.8L
0.8Y
NC 6 MCU 30A
CN-56
24V(PRES.SENSOR) 7 3
4
START KEY 30A
GND(PRES.SENSOR) 8 4
RR
W 20A
ALT LEVEL 9 AIR CON/HEATER
5
P1 PRESS SIG. 10 WIPER 10A
P2 PRESS SIG. 11 6
SPARE 10A
5R
P3 PRESS SIG. 12 7
TX
RX
GND
TRAVEL PS 13 CLUSTER 10A
O/T DECEL SW 14
8
20A
POWER IG(24V)
MCU CONT.
CLUSTER
WATER LEVEL SW 15 9
AIR CLEANER SW 16 FUEL CUT OFF 10A
10
NC 17 SWITCH PANEL 10A
NC 18 11
CASSETTE 10A
NC 19 12
GND (POT&DIAL) 20 SPARE 30A
5V (POT&DIAL)
13
21 20A
CONVERTER
22 14
WORK LAMP 30A
CN-50 15
MCU
BOOM PRIORITY SOL 1 16
MAX FLOW SOL. 2 WIPER 10A
17
POWER MAX SOL. 3 20A
HEAD LAMP
HOUR-METER 4 18
FUEL HEATER 30A
ENG PREHEATER 5 19
CHARGING CIRCUIT (CLUSTER TYPE 2)
FUEL HEATER 6 START,STOP 30A

20
5W
BATTERY 24V(+) 7
HORN 10A
PUMP EPPR(-) 8 21
AC& HEATER 20A
145
NC 9
22
10 10A
0.8B
SAFETY SOL
0.8W
4-19
NC 25 23
OPTION 20A
NC 26 24
20A
3
2
9
8
7
6
5
4
1
NC
12
11
10
27 SOLENOIDE
25
CN-3
GND (MAIN) 28 20A
Y 1.2B CIGAR
SERIAL-TX 29 26
0.8B
L OPTION(BEACON) 20A
SERIAL-RX 30
27
GND 31 20A
2
TRAVEL SOL
1
RS232 (+) 32 28
CR-1
DO-3
B
PRE-HEAT 10A
Gr
RS232 (-) 33 29
DIODE
20A
2
BATT RY
RS232 (GND) 34 FUEL P/P
NC
30
35 10A
SPARE
3W/300
1
2
PUMP EPPR(+) 36 31
FUSE BOX
2
1
RS-1
1
CS-74A
60R
CR-23
5R
1
START RY
1
2
1
2
5R
CN-60
CN-95
2
CS-74
5R
5R
5W
5W
MASTER SW
FUSIBLE LINK
(12VX2)
BATTERY
60B
1.2W
3
B+
CN-45
15 R
4
3
2
1
M
L
P
FI
B+
NC
ALT
STARTER
CN-74
3
~
G
3309S4EL12
4. HEAD AND WORK LIGHT CIRCUIT (CLUSTER TYPE 1)
1) OPERATING FLOW
Fuse box (No.15) Work light relay [CR-4 (30, 86)]
Fuse box (No.18) Head light relay [CR-13 (30, 86)]
(1) Head light switch ON
Head light switch ON [CN-116 (1)] l/conn [CN-5 (49)] Head light relay [CR-13 (85) → (87)]
Head light ON [CL-3 (1), CL-4 (1)]
l/conn [CN-11 (8)] AC & Heater controller illumination ON [4]
l/conn [CN-5 (13)] Cassette radio illumination ON [CN-27 (9)]
Cigar light [CL-2]
l/conn [CN-8 (7)] Accel dial LED ON
(2) Work light switch ON

Work light switch ON [CN-116 (2)] l/conn [CN-5 (50)] Work light relay [CR-4 (85) → (87)]
l/conn [CN-12 (1)] Work light ON [CL-5 (2), CL-6 (2)]
2) CHECK POINT
① - GND (fuse box)

② - GND (switch power output)
③ - GND (head light relay)
④ - GND (head light)
STOP ON 20~25V
⑤ - GND (fuse box)
⑥- GND (switch power output)
⑦ - GND (work light relay)
⑧ - GND (work light)
※ GND : Ground
4-20
ACCEL DIAL LED
NC
GND
2
1
IG 24V
CN-279
CN-36
POWER IG
BATTERY(+)
IG POWER 30A
ILLUMINATION
ILLUMINATION
REVERSE FAN
1
0.8B
INCAR SENSOR
POWER TR BASE
W/TEMP SENSOR
0.8ROr
DUCT SENSOR(+)
AMBIENT SENSOR
2
MCU 30A
DUCT SENSOR(GND)
3
START KEY 30A
4
20A
9
8
7
6
5
4
3
2
1
AIR CON/HEATER
14
13
12
11
10
5
WIPER 10A
6
CLUSTER 10A
7
CLUSTER 10A
CN-5 8
20A
AC & HEATER CONTROLLER(AUTO)

MCU CONT.
0.8ROr
1 9
MCU_EPPR 20A
2 10
2
2
5
5
7
6
4
1
4
1
8
7
6
3
3
12
11
10
SWITCH PANEL 10A
3
CN-8
11
CN-11
CASSETTE 10A
CN-27 4 12
0.8
1
ACC 1 FUEL CUT-OFF SOL. 10A
5
0.8ROr
13
ILL- 2 6 CONVERTER 20A
14
NC 3 7 2RW WORK LAMP 30A
15
SPK FRT RH- 4 8 CABIN LAMP(OPTION) 30A
16
SPK FRT LH- 5 9 10A
WIPER
TEL MUTE 6 10 17
1.2Br HEAD LAMP 20A
ANT 12V 7 11 18
FUEL HEATER 30A
BACK UP+ 8 12 19
0.8ROr 0.8ROr 0.8ROr START,STOP 30A
ILL+ 9 13 20
10A
5
HORN
NC 10 14 21
AC& HEATER 20A
SPK FRT RH+ 11 15
CASSETTE RADIO
22
4-21
REMOCON+ 12 16 SAFETY SOL 10A
23
REMOCON GND 13 17 OPTION 20A
24
SPK FRT LH+ 14 18 SOLENOIDE 20A
CL-2 25
NC 15 19 CIGAR 20A
26
GND 16 20 OPTION(BEACON) 20A
HEAD AND WORK LIGHT CIRCUIT (CLUSTER TYPE 1)
21 27
ROr TRAVEL SOL 20A
28
41 PRE-HEAT 10A
CIGAR LIGHT
42 29
FUEL P/P 20A
43 30
SPARE 10A
44 31
8
FUSE BOX
45
2B
2RG
2
46
47
1
2
CN-116 48
CN-12
0.8BrW 0.8BrW 0.8BrW

HEAD LIGHT OUT 1 49
0.8VW 0.8VW 0.8VW
WORK LIGHT OUT 2 50
INT. SIG 3 51
7
WIPER MOTOR DRIVE 4 52

WASHER SIG 5 53
6
0.8Br
0.8RW
3 4
3 4
PRE-HEAT 6 54
V
B
V
B
1.2ROr
2RG
0.8BrW
0.8VW
1.2B
1.2B
2RW
1.2Br
1.2ROr
1.2ROr
CABIN LIGHT OUT 7 55

TRAVEL ALARM 8 56
1
1
2
2
1
87
87
2
85
85
1
86
86
2
30
30
87a
87a
CL-4
CL-3
CL-6
57
CR-4
CL-5
NC 9
SWITCH PANEL
CR-13
POWER 24V 10 58
GND 11 59
HEAD LAMP
HEAD LAMP
30 86
30 86
87a 87 85
87a 87 85
NC 12 60
WORK LAMP
HEAD LAMP RY
WORK LAMP RY
3309S4EL13
■ HEAD AND WORK LIGHT CIRCUIT (CLUSTER TYPE 2)
1) OPERATING FLOW
Fuse box (No.15) Work light relay [CR-4 (30, 86)]
Fuse box (No.18) Head light relay [CR-13 (30, 86)]
(1) Head light switch ON
Head light switch ON [CN-116 (1)] l/conn [CN-5 (49)] Head light relay [CR-13 (85) → (87)]
Head light ON [CL-3 (1), CL-4 (1)]
l/conn [CN-11 (8)] AC & Heater controller illumination ON [4]
l/conn [CN-5 (13)] Cassette radio illumination ON [CN-27 (9)]
Cigar light [CL-2]
l/conn [CN-8 (7)] Accel dial LED ON
(2) Work light switch ON

Work light switch ON [CN-116 (2)] l/conn [CN-5 (50)] Work light relay [CR-4 (85) → (87)]
l/conn [CN-12 (1)] Work light ON [CL-5 (2), CL-6 (2)]
2) CHECK POINT

② - GND (switch power output)
③ - GND (head light relay)
④ - GND (head light)
STOP ON 20~25V
⑥- GND (switch power output)
⑦ - GND (work light relay)
⑧ - GND (work light)
※ GND : Ground
4-22
ACCEL DIAL LED
NC
GND
2
1
IG 24V
CN-279
CN-36
POWER IG
BATTERY(+)
IG POWER 30A
ILLUMINATION
ILLUMINATION
REVERSE FAN
1
0.8B
INCAR SENSOR
POWER TR BASE
W/TEMP SENSOR
0.8ROr
DUCT SENSOR(+)
AMBIENT SENSOR
2
MCU 30A
DUCT SENSOR(GND)
3
START KEY 30A
4
20A
9
8
7
6
5
4
3
2
1
AIR CON/HEATER
14
13
12
11
10
5
WIPER 10A
6
SPARE 10A
7
CLUSTER 10A
CN-5 8
20A
AC & HEATER CONTROLLER(AUTO)

MCU CONT.
0.8ROr
1 9
FUEL CUT OFF 10A
2 10
2
2
5
5
7
6
4
1
4
1
8
7
6
3
3
12
11
10
SWITCH PANEL 10A
3
CN-8
11
CN-11
CASSETTE 10A
CN-27 4 12
0.8
1
ACC 1 SPARE 30A
5
0.8ROr
13
ILL- 2 6 CONVERTER 20A
14
NC 3 7 2RW WORK LAMP 30A
15
SPK FRT RH- 4 8 CABIN LAMP(OPTION) 30A
16
SPK FRT LH- 5 9 10A
WIPER
TEL MUTE 6 10 17
1.2Br HEAD LAMP 20A
ANT 12V 7 11 18
FUEL HEATER 30A
BACK UP+ 8 12 19
0.8ROr 0.8ROr 0.8ROr START,STOP 30A
ILL+ 9 13 20
10A
5
HORN
NC 10 14 21
AC& HEATER 20A
SPK FRT RH+ 11 15
CASSETTE RADIO
22
10A
4-23
REMOCON+ 12 16 SAFETY SOL
23
REMOCON GND 13 17 OPTION 20A
24
SPK FRT LH+ 14 18 SOLENOIDE 20A
CL-2 25
NC 15 19 CIGAR 20A
26
GND 16 20 OPTION(BEACON) 20A
HEAD AND WORK LIGHT CIRCUIT (CLUSTER TYPE 2)
21 27
ROr TRAVEL SOL 20A
28
41 PRE-HEAT 10A
CIGAR LIGHT
42 29
FUEL P/P 20A
43 30
SPARE 10A
44 31
8
FUSE BOX
45
2B
2RG
2
46
47
1
2
CN-116 48
CN-12
0.8BrW 0.8BrW 0.8BrW

HEAD LIGHT OUT 1 49
0.8VW 0.8VW 0.8VW
WORK LIGHT OUT 2 50
INT. SIG 3 51
7

WASHER SIG 5 53
6
0.8Br
0.8RW
3 4
3 4
PRE-HEAT 6 54
V
B
V
B
1.2ROr
2RG
0.8BrW
0.8VW
1.2B
1.2B
2RW
1.2Br
1.2ROr
1.2ROr

TRAVEL ALARM 8 56
1
1
2
2
1
87
87
2
85
85
1
86
86
2
30
30
87a
87a
CL-3
CL-6
57
CL-4
CR-4
CL-5
NC 9
SWITCH PANEL
CR-13
POWER 24V 10 58
GND 11 59
HEAD LAMP
HEAD LAMP
30 86
30 86
87a 87 85
87a 87 85
NC 12 60
WORK LAMP
HEAD LAMP RY
WORK LAMP RY
3309S4EL14
5. BEACON LAMP AND CAB LIGHT CIRCUIT (CLUSTER TYPE 1)
1) OPERATING FLOW
Fuse box (No. 27) I/conn [CN-5 (33)] Beacon lamp switch [CN-23 (8)]
Fuse box (No.16) Cab light relay [CR-9 (30, 86)]
(1) Beacon lamp switch ON
Beacon lamp switch ON [CS-23 (4)] Switch indicator lamp ON [CS-23 (11)]
l/conn [CN-10 (10)] Beacon lamp ON [CL-7]
(2) Cab light switch ON
Cab light switch ON [CN-116 (7)] I/conn [CN-5 (55)] Cabin light relay [CR-9 (85) → (87)]
I/conn [CN-5 (34)] I/conn [CN-10 (11, 12)] Cab light ON [CL-8 (2), CL-9 (2)]
2) CHECK POINT

② - GND (switch power input)
③ - GND (switch power output)
④ - GND (beacon lamp)
STOP ON 20~25V
⑥ - GND (cab light relay)
⑦ - GND (switch power output)
⑧ - GND (cab light)
※ GND : Ground
4-24
CN-36
IG POWER 30A
1
2
MCU 30A
12
M
3
4
9
12
10
3
CL-7
CL-9
CL-8
START KEY 30A
4
AIR CON/HEATER 20A
2
2
1
1
5
WIPER 10A
CAB LIGHT-LH
7
8
CAB LIGHT-RH
2
11
6
BEACON LAMP
CLUSTER 10A
1.2B
7
1.2B
2.0V
2.0V
1.2B
10
11
5
9
12
4
8
4
1
2
3
6
7
1.2BrW
CLUSTER 10A
CS-23
8
BEACON LAMP SW
8
MCU CONT. 20A
9
0.8B
MCU_EPPR 20A
1.2BrW
1.2Br
0.8BrW
10
SWITCH PANEL 10A
11
10A
3
CASSETTE
12
2
FUEL CUT-OFF SOL. 10A
13
5
CONVERTER 20A
14
WORK LAMP 30A
15
5
4
1
9
8
7
6
3
12
11
10
2R CABIN LAMP(OPTION) 30A
16
CN-10
CN-5
WIPER 10A
1 17
HEAD LAMP 20A
2 18
FUEL HEATER 30A
3 19
4 START,STOP 30A
20
5 HORN 10A
21
6 AC& HEATER 20A
22
7 SAFETY SOL 10A
23
8 20A
4-25
1.2B 1.2B OPTION
30 24
1
1.2B 1.2B SOLENOIDE 20A

31 25
CIGAR 20A
32 26
1.2Br 1.2Br 1.2Br OPTION(BEACON) 20A
33 27
1.2V 1.2V TRAVEL SOL 20A
34 28
PRE-HEAT 10A
35 29
FUEL P/P 20A
36 30
37 SPARE 10A
CN-116 0.8V 0.8V 31
FUSE BOX
1 38
HEAD LIGHT OUT
BEACON LAMP AND CAB LIGHT CIRCUIT (CLUSTER TYPE 1)
2 39
WORK LIGHT OUT
INT. SIG 3 51
WIPER MOTOR DRIVE 52
7
4
WASHER SIG 5 53
PRE-HEAT 6 54
0.8Gr 0.8Gr 0.8Gr
6

TRAVEL ALARM 8 56
0.8R
NC 9 57
2V
SWITCH PANEL
0.8Gr
58
2R
POWER 24V 10
GND 11 59
87
85
86
30
NC 12 60
87a
CR-9
30 86
87a 87 85
CABIN LAMP RY
3309S4EL15
■ BEACON LAMP AND CAB LIGHT CIRCUIT (CLUSTER TYPE 2)
1) OPERATING FLOW
Fuse box (No. 27) I/conn [CN-5 (33)] Beacon lamp switch [CN-23 (8)]
Fuse box (No.16) Cab light relay [CR-9 (30, 86)]
(1) Beacon lamp switch ON
Beacon lamp switch ON [CS-23 (4)] Switch indicator lamp ON [CS-23 (11)]
l/conn [CN-10 (10)] Beacon lamp ON [CL-7]
(2) Cab light switch ON
Cab light switch ON [CN-116 (7)] I/conn [CN-5 (55)] Cabin light relay [CR-9 (85) → (87)]
I/conn [CN-5 (34)] I/conn [CN-10 (11, 12)] Cab light ON [CL-8 (2), CL-9 (2)]
2) CHECK POINT

④ - GND (beacon lamp)
STOP ON 20~25V
⑥ - GND (cab light relay)
⑦ - GND (switch power output)
⑧ - GND (cab light)
※ GND : Ground
4-26
CN-36
IG POWER 30A
1
2
MCU 30A
12
M
3
4
9
12
10
3
CL-7
CL-9
CL-8
START KEY 30A
4
AIR CON/HEATER 20A
2
2
1
1
5
WIPER 10A
CAB LIGHT-LH
7
8
CAB LIGHT-RH
2
11
6
BEACON LAMP
SPARE 10A
1.2B
7
1.2B
2.0V
2.0V
1.2B
10
11
5
9
12
4
8
4
1
2
3
6
7
1.2BrW
CLUSTER 10A
CS-23
8
BEACON LAMP SW
8
MCU CONT. 20A
9
0.8B
FUEL CUT OFF 10A
1.2BrW
1.2Br
0.8BrW
10
SWITCH PANEL 10A
11
10A
3
CASSETTE
12
2
SPARE 30A
13
5
CONVERTER 20A
14
WORK LAMP 30A
15
5
4
1
9
8
7
6
3
12
11
10
2R CABIN LAMP(OPTION) 30A
CN-5 16
CN-10
WIPER 10A
1 17
HEAD LAMP 20A
2 18
FUEL HEATER 30A
3 19
4 START,STOP 30A
20
5 HORN 10A
21
6 AC& HEATER 20A
22
7 SAFETY SOL 10A
23
8 20A
4-27
1.2B 1.2B OPTION
30 24
1
1.2B 1.2B SOLENOIDE 20A

31 25
CIGAR 20A
32 26
1.2Br 1.2Br 1.2Br OPTION(BEACON) 20A
33 27
1.2V 1.2V TRAVEL SOL 20A
34 28
PRE-HEAT 10A
35 29
FUEL P/P 20A
36 30
37 SPARE 10A
CN-116 0.8V 0.8V 31
FUSE BOX
1 38
HEAD LIGHT OUT
BEACON LAMP AND CAB LIGHT CIRCUIT (CLUSTER TYPE 2)
2 39
WORK LIGHT OUT
INT. SIG 3 51
WIPER MOTOR DRIVE 52
7
4
WASHER SIG 5 53
PRE-HEAT 6 54
0.8Gr 0.8Gr 0.8Gr
6

TRAVEL ALARM 8 56
0.8R
NC 9 57
2V
SWITCH PANEL
0.8Gr
58
2R
POWER 24V 10
GND 11 59
87
85
86
30
NC 12 60
87a
CR-9
30 86
87a 87 85
CABIN LAMP RY
3309S4EL16
6. WIPER AND WASHER CIRCUIT (CLUSTER TYPE 1)
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.11) I/conn [CN-5 (57)] Switch panel [CN-116 (10)]
Fuse box (No.6) I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller [CN-141(7)]
Wiper motor [CN-21(4)]
Fuse box (No.17) I/conn [CN-5 (24)] l/conn [CN-17 (4)] Wiper motor controller [CN-141 (6)]
Washer pump [CN-22 (2)]
(2) Wiper switch ON : 1st step (Intermittent)
Wiper switch ON [CN-116 (3)] I/conn [CN-17 (8)] Wiper motor controller [CN-141 (10) → (3)]
Wiper motor intermittently operating [CN-21 (6)]
(3) Wiper switch ON : 2nd step (continual)
Wiper switch ON [CN-116(4)] I/conn[CN-17(2)] Wiper motor controller [CN-141(2) → (4)]
Wiper motor operating [CN-21(2)]
(4) Washer switch ON
Washer switch ON [CN-116 (5)] I/conn [CN-17 (7)] Wiper motor controller [CN-141 (9) → (8)]
I/conn [CN-17 (6)] I/conn [CN-5 (19)] Washer pump [CN-22 (1)] Washer operating
Wiper switch ON [CN-116 (4)] I/conn[CN-17 (2)] Wiper motor controller [CN-141 (2) → (4)]
Wiper motor operating [CN-21 (2)]
(5) Auto parking
parking(when switch OFF)
Switch OFF [CN-116 (4)] Wiper motor parking position by wiper motor controller
2) CHECK POINT

24V
STOP ON 0 ~ 5V
④ - GND (wiper power input)
⑤ - GND (wiper power output) 24V
⑥ - GND (wiper motor) 0 or 24V
※ GND : Ground
4-28
CN-5
1
2
3
4 CN-36
5 IG POWER 30A
6
CN-21 6 1
1 CS-53 7 2
3 Or
R MCU 30A
2 8 3
Gr START KEY 30A
5 3 9 4
R 20A
4 10 AIR CON/HEATER
4 G B
5
5 11 0.8R WIPER 10A
WIPER CUT SW
L 6
6 M 2 6 12 CLUSTER 10A
WIPER MOTOR
7
13 CLUSTER 10A
8
1
14 20A
MCU CONT.
15 9
MCU_EPPR 20A
16 10
4
0.8RW SWITCH PANEL 10A
17 11
0.8R 0.8R 10A
CN-141 18 CASSETTE
G 0.8V 0.8V 12
FEED BACK 1 19 FUEL CUT-OFF SOL. 10A
W 13
1
MOTOR DRIVE SIG 2 CN-17 20 CONVERTER 20A
L 14
MOTOR DRIVE- 3 1 21 WORK LAMP 30A
R W 0.8W
MOTOR DRIVE+ 4 2 22 15
B B 1.2B CABIN LAMP(OPTION) 30A
GND 5 3 23 16
GrW GrW 0.8ROr 0.8ROr 0.8GrW 0.8GrW WIPER 10A
VCC 6 4 24 17
R R 0.8R HEAD LAMP 20A
CONTINUE 24V 7 5 25 18
V V 0.8V 30A
WASHER P/P 8 6 26 FUEL HEATER
19
1
L L 0.8L
WASHER SIG. 9 7 27 START,STOP 30A
Br Br 0.8Br 20
INT. SIG 10 8 28 HORN 10A
Or 21
WIPER CUT SW 11 29 AC& HEATER 20A
1.2B 1.2B 22
N.C 12 30 10A
SAFETY SOL

Gr 1.2B 1.2B
FEED BACK 13 31 23
4-29
OPTION 20A
32 24
SOLENOIDE 20A
5
33 25
CIGAR 20A
34 26
WIPER AND WASHER CIRCUIT (CLUSTER TYPE 1)
35 OPTION(BEACON) 20A
27
36 TRAVEL SOL 20A
28
37 PRE-HEAT 10A
29
38 FUEL P/P 20A
39 30
SPARE 10A
40 31
FUSE BOX
41
42
0.8V
0.8V
0.8GrW
0.8GrW
43
2
1
44
2
1
DO-5
45
CN-22
M
DIODE
46
CN-116 47
HEAD LIGHT OUT 1
WASHER PUMP
48
WORK LIGHT OUT 2
0.8Br 49
INT. SIG 3 50
0.8W
0.8L
WASHER SIG 5 52
PRE-HEAT 6 53
3
TRAVEL ALARM 8 55
NC 9 56
SWITCH PANEL
0.8RW 0.8RW 0.8RW
POWER 24V 10 57
GND 11 58
NC 12 59
3309S4EL17
60
2
■ WIPER AND WASHER CIRCUIT (CLUSTER TYPE 2)
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.11) I/conn [CN-5 (57)] Switch panel [CN-116 (10)]
Fuse box (No.6) I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller [CN-141(7)]
Wiper motor [CN-21(4)]
Fuse box (No.17) I/conn [CN-5 (24)] l/conn [CN-17 (4)] Wiper motor controller [CN-141 (6)]
Washer pump [CN-22 (2)]
(2) Wiper switch ON : 1st step (Intermittent)
Wiper switch ON [CN-116 (3)] I/conn [CN-17 (8)] Wiper motor controller [CN-141 (10) → (3)]
Wiper motor intermittently operating [CN-21 (6)]
(3) Wiper switch ON : 2nd step (continual)
Wiper switch ON [CN-116(4)] I/conn[CN-17(2)] Wiper motor controller [CN-141(2) → (4)]
Wiper motor operating [CN-21(2)]
(4) Washer switch ON
Washer switch ON [CN-116 (5)] I/conn [CN-17 (7)] Wiper motor controller [CN-141 (9) → (8)]
I/conn [CN-17 (6)] I/conn [CN-5 (19)] Washer pump [CN-22 (1)] Washer operating
Wiper switch ON [CN-116 (4)] I/conn[CN-17 (2)] Wiper motor controller [CN-141 (2) → (4)]
Wiper motor operating [CN-21 (2)]
(5) Auto parking
parking(when switch OFF)
Switch OFF [CN-116 (4)] Wiper motor parking position by wiper motor controller
2) CHECK POINT

24V
STOP ON 0 ~ 5V
④ - GND (wiper power input)
⑤ - GND (wiper power output) 24V
⑥ - GND (wiper motor) 0 or 24V
※ GND : Ground
4-30
CN-5
1
2
3
4 CN-36
5 IG POWER 30A
6
CN-21 6 1
3 1 CS-53 7 2
R Or MCU 30A
2 8 3
Gr START KEY 30A
5 3 9 4
R 20A
4 10 AIR CON/HEATER
4 G B
5
5 11 0.8R WIPER 10A
WIPER CUT SW
L 6
6 M 2 6 12 SPARE 10A
WIPER MOTOR
7
13 CLUSTER 10A
8
1
14 20A
MCU CONT.
15 9
FUEL CUT OFF 10A
16 10
4
0.8RW SWITCH PANEL 10A
17 11
0.8R 0.8R 10A
CN-141 18 CASSETTE
G 0.8V 0.8V 12
FEED BACK 1 19 SPARE 30A
W 13
1
MOTOR DRIVE SIG 2 CN-17 20 CONVERTER 20A
L 14
MOTOR DRIVE- 3 1 21 WORK LAMP 30A
R W 0.8W
MOTOR DRIVE+ 4 2 22 15
B B 1.2B CABIN LAMP(OPTION) 30A
GND 5 3 23 16
GrW GrW 0.8ROr 0.8ROr 0.8GrW 0.8GrW WIPER 10A
VCC 6 4 24 17
R R 0.8R HEAD LAMP 20A
CONTINUE 24V 7 5 25 18
V V 0.8V 30A
WASHER P/P 8 6 26 FUEL HEATER
19
1
L L 0.8L
WASHER SIG. 9 7 27 START,STOP 30A
Br Br 0.8Br 20
INT. SIG 10 8 28 HORN 10A
Or 21
WIPER CUT SW 11 29 AC& HEATER 20A
1.2B 1.2B 22
N.C 12 30 10A
SAFETY SOL

Gr 1.2B 1.2B
FEED BACK 13 31 23
4-31
OPTION 20A
32 24
SOLENOIDE 20A
5
33 25
CIGAR 20A
34 26
WIPER AND WASHER CIRCUIT (CLUSTER TYPE 2)
35 OPTION(BEACON) 20A
27
36 TRAVEL SOL 20A
28
37 PRE-HEAT 10A
29
38 FUEL P/P 20A
39 30
SPARE 10A
40 31
FUSE BOX
41
42
0.8V
0.8V
0.8GrW
0.8GrW
43
2
1
44
2
1
DO-5
45
CN-22
M
DIODE
46
CN-116 47
HEAD LIGHT OUT 1
WASHER PUMP
48
WORK LIGHT OUT 2
0.8Br 49
INT. SIG 3 50
0.8W
0.8L
WASHER SIG 5 52
PRE-HEAT 6 53
3
TRAVEL ALARM 8 55
NC 9 56
SWITCH PANEL
0.8RW 0.8RW 0.8RW
POWER 24V 10 57
GND 11 58
NC 12 59
3309S4EL18
60
2
CN-76
M- 6
6 5
M M+ 5
NC 4
2 B
P- 3
3 1
-
+
S
SIG 2
0.8Gr
GOV. MOTOR
P+ 1
ACCEL DIAL
B
A
C
CN-142
B
W
Gr
2
5
4
1
9
8
7
6
3
16
15
14
13
12
11
10
CN-51
CN-7
1.2
BATT POWER_24V 1
1.2R
RH CONSOLE
POWER IG 2
POWER_24V OUT 3
TACHO SENSOR+ 4
1.2B CN-36
GND_5V 5
0.8Gr 30A
POWER_5V OUT 6 IG POWER
1
G/A MOTOR(+) 7 ROOM LAMP/CASSETTE 10A
G/A MOTOR(-) 8 2
1.2R MCU 30A
nc 9 3
START KEY 30A
nc 10 4
GND_MAIN 11 AIR CON/HEATER 20A
5
CAN_SHIELD 12 WIPER 10A
GND_RETURN 13 6
CLUSTER 10A
SPEED SENSOR+(HMC) 14 7
TACHO SENSOR- CLUSTER 10A
15
8
PROGRAM DUMP 16 1.2RW MCU CONT. 20A
ONE TOUCH DECEL
9
17 1.2R 20A
MCU_EPPR
POWER BOOST SW 18 10
SWITCH PANEL 10A
HOUR METER 19 11
ANTI RESTART RY 20 CASSETTE 10A
12
CAN1 Hi 21 FUEL CUT-OFF SOL. 10A
nc 22
13
CONVERTER 20A
RS485+(TX)-CLUSTER 23 14
WORK LAMP 30A
CONTROLLER CIRCUIT (CLUSTER TYPE 1)
24 15
16
10A
4-32
WIPER
MCU
17
CN-52 HEAD LAMP 20A
18
ARM REGEN SOL 1 FUEL HEATER 30A
POWER MAX SOL
19
2 30A
START,STOP
TRAVEL SPEED SOL 3 20
HORN 10A
ATT_ SAFETY SOL 4 21
ATT_PRESS SOL. 5 AC& HEATER 20A
22
ATT_CONFLUX SOL. 6 SAFETY SOL 10A
BOOM PRIORITY EPPR+ 7 23
0.8 OPTION 20A
POWER IG EPPR 8 24
0.8 SOLENOIDE 20A
PUMP POWER EPPR+ 9 25
ATT. EPPR+ 10 CIGAR 20A
26
nc 11 OPTION(BEACON) 20A
FUEL WARMER RY 12 27
TRAVEL SOL 20A
TRAVEL BUZZER 13 28
ENG STOP RY PRE-HEAT 10A
14
29
ENG PRE-HEAT RY 15 FUEL P/P 20A
nc
30
16 SPARE 10A
BOOM PRIORITY EPPR- 17 31
FUSE BOX
EPPR GND 18
0.8
PUMP POWER EPPR- 19
ATT. EPPR- 20
nc 21
nc 22
0.8
Br
Or
ACCEL DIAL SIG 23
24
5
4
1
9
8
7
6
3
15
14
13
12
11
10
CN-2
Br
Or
3309S4EL19
2
1
CN-75
EPPR V/V
CN-76
M- 6
6 5
M M+ 5
NC 4
2 B
P- 3
3 1
SIG 2
0.8Gr
GOV. MOTOR
P+ 1
-
+
ACCEL DIAL
B
A
C
CN-142
CN-51
B
W
Gr
WORKING PS 1
POWER MAX SW 2
TRAVEL ALARM SW 3
ENG OIL PS
5
4
4
1
9
8
7
6
3
16
15
14
13
12
11
10
CN-7
NC 5
NC 6
RH CONSOLE
24V(PRES.SENSOR) 7
GND(PRES.SENSOR) 8
ALT LEVEL 9 CN-36
P1 PRESS SIG. 10 30A
IG POWER
P2 PRESS SIG. 11 1
P3 PRESS SIG. 12 2
TRAVEL PS 13 1.2R MCU 30A
3
O/T DECEL SW 14 START KEY 30A
WATER LEVEL SW 15 4
AIR CON/HEATER 20A
AIR CLEANER SW 16 5
WIPER 10A
NC 17 6
NC 18 SPARE 10A
7
NC 19 10A
B CLUSTER
GND (POT&DIAL) 20 8
G/OR 1.2RW MCU CONT. 20A
5V (POT&DIAL) 21 9
POT-SIG FUEL CUT OFF 10A
22
W 10
ACCEL DIAL SIG 23 SWITCH PANEL 10A
11
CASSETTE 10A
TACHO SENSOR(-) 25 12
SPARE 30A
26 13
CONVERTER 20A
CONTROLLER CIRCUIT (CLUSTER TYPE 2)
CN-50 14
MCU
WORK LAMP 30A
BOOM PRIORITY SOL 1 15
4-33
MAX FLOW SOL. 2 16
POWER MAX SOL. 3 WIPER 10A
17
HOUR-METER 4 20A
HEAD LAMP
ENG PREHEATER 5 18
FUEL HEATER 30A
FUEL HEATER 6 19
GY START,STOP 30A
BATTERY 24V(+) 7
BR 20
PUMP EPPR(-) 8 HORN 10A
NC
21
9 20A
AC& HEATER
PROGRAM DUMP 10 22
SAFETY SOL 10A
ANTI-RESTART RY 11 23
ACCEL ACT(+) 12 OPTION 20A
24
TRAVEL SPEED SOL. 13 SOLENOIDE 20A
NC 14
25
CIGAR 20A
NC 15 26
OPTION(BEACON) 20A
TRAVEL BUZZER 16 27
PRE-HEAT SW 17 TRAVEL SOL 20A
28
NC 18 PRE-HEAT 10A
NC 19 29
FUEL P/P 20A
OVERLOAD SIG 20 30
ENGINE OIL FILTER SPARE 10A
21
31
FUSE BOX
HOUR-METER 22
ACCEL ACT(-) 23
OR
POWER IG 24
NC 25
NC 26
Br
Or
NC 27
GND (MAIN) 28
SERIAL-TX 29
5
4
1
9
8
7
6
3
15
14
13
12
11
10
SERIAL-RX 30
CN-2
GND 31
RS232 (+) 32
RS232 (-) 33
RS232 (GND) 34
Br
Or
NC 35
OR
3309S4EL20
PUMP EPPR(+) 36
1
2
CN-75
EPPR V/V
CN-51
BATT POWER_24V 1
POWER IG 2
POWER_24V OUT 3
TACHO SENSOR+ 4
GND_5V 5
Pa
POWER_5V OUT 6
CD-10
C 1
2
G/A MOTOR(+) 7
2
1
CD-1
HYD TEMP
G/A MOTOR(-) 8
FUEL LEVER
CD-2
nc 9
1.2B
0.8
0.8
1.2YOr
AIR CLEANER SW
0.8B
0.8B
nc 10
GND_MAIN 11
CAN_SHIELD 12 CN-36
GND_RETURN 13 30A
IG POWER
SH
0.8Gr
0.8L
0.8Y
0.8RW
0.8L
0.8Y
0.8Gr
0.8RW
TACHO SENSOR- 15 2
MCU 30A
5
4
1
9
8
7
6
PROGRAM DUMP
3
16
60
59
58
57
24
23
22
21
20
19
18
17
3
CN-5
ONE TOUCH DECEL
8
7
6
5
4
3
2
1
17 START KEY 30A
4
CN-56
POWER BOOST SW 18 20A
SH
AIR CON/HEATER
0.8L
0.8Y
L
Gr
HOUR METER
Y
B
W
5
0.8Gr
19
WL
WR
RW
0.8RW
WIPER 10A
ANTI RESTART RY 20 6
CAN1 Hi 21 0.8RW CLUSTER 10A
7
nc 22 10A
TX
0.8Gr
RX
0.8L CLUSTER
SIG_2
GND
SIG_3
8
IG 24V
BATT.24V
MCU CONT. 20A
RS232C1_TX-HRDT 24 9
CAMERA SIG
CLUSTER
RS232C2_TX-RCM MCU_EPPR 20A
25 10
TRAVEL ALARM SELECT SIG 26 SWITCH PANEL 10A
ENG OIL PS
11
27 CASSETTE 10A
coolent level 28 12
0.8GrW FUEL CUT-OFF SOL. 10A
AIR CLEANER SW(NO) 29 13
BLOWER SIG. 30 CONVERTER 20A
14
CAN1 Lo 31 WORK LAMP 30A
nc
15
32 30A
0.8Y CABIN LAMP(OPTION)
RS485-(RX)-CLUSTER 16
MONITORING CIRCUIT (CLUSTER TYPE 1)
33
WIPER 10A
RS232C1_RX-HRDT 34 17
RS232C2_RX-RCM 35 HEAD LAMP 20A
18
4-34
PRE-HEAT SELECT SIG 36 FUEL HEATER 30A
ENGINE OIL FILTER 37
19
START,STOP 30A
nc 38 20
HORN 10A
nc 39 21
nc 40 AC& HEATER 20A
22
SAFETY SOL 10A
CN-52 23
MCU
OPTION 20A
ARM REGEN SOL 1 24
POWER MAX SOL 2 SOLENOIDE 20A
25
TRAVEL SPEED SOL 3 CIGAR 20A
OPTION(BEACON) 20A
ATT_PRESS SOL. 5 27
TRAVEL SOL 20A
ATT_CONFLUX SOL. 6 28
BOOM PRIORITY EPPR+ 7 PRE-HEAT 10A
29
POWER IG EPPR 8 FUEL P/P 20A
PUMP POWER EPPR+ 9 30
SPARE 10A
ATT. EPPR+ 10 31
FUSE BOX
nc 11
FUEL WARMER RY 12
TRAVEL BUZZER 13
ENG STOP RY 14
ENG PRE-HEAT RY 15
nc 16
BOOM PRIORITY EPPR- 17
EPPR GND 18
PUMP POWER EPPR- 19
ATT. EPPR- 20
nc 21
nc 22
ACCEL DIAL SIG 23
0.8
HYD. TEMP SENDER 24
WATER TEMP SENDOR 25
0.8OrW
3309S4EL21
27
Pa
CD-10
C 1
2
2
1
CD-1
HYD TEMP
FUEL LEVER
CD-2
1.2B
0.8
0.8
1.2YOr
AIR CLEANER SW
0.8B
0.8B
CN-51 CN-36
SH
L
Y
B
WORKING PS 1 30A
Br
0.8L
0.8B
0.8Y
IG POWER
0.8Gr
POWER MAX SW 2 1
TRAVEL ALARM SW 3 2
MCU 30A
5
4
1
9
8
7
6
3
60
59
58
57
24
23
22
21
20
19
18
17
ENG OIL PS 4
3
4
3
2
1
CN-5
NC 5 START KEY 30A
CN-56
NC
4
6 20A
AIR CON/HEATER
SH
RR
5
0.8L
24V(PRES.SENSOR)
0.8B
0.8Y
7
0.8Gr
WIPER 10A
GND(PRES.SENSOR) 8 6
ALT LEVEL 9 SPARE 10A
7
P1 PRESS SIG. 10 0.8Gr CLUSTER 10A
8
TX
RX
P2 PRESS SIG. 11
GND
MCU CONT. 20A
P3 PRESS SIG. 12 9
10A
POWER IG(24V)
FUEL CUT OFF
CLUSTER
TRAVEL PS 13 10
O/T DECEL SW 14 SWITCH PANEL 10A
11
WATER LEVEL SW 15 CASSETTE 10A
L
AIR CLEANER SW 16 12
SPARE 30A
NC 17 13
NC CONVERTER 20A
18 14
NC 19 WORK LAMP 30A
GND (POT&DIAL)
15
20 CABIN LAMP(OPTION) 30A
5V (POT&DIAL) 21 16
WIPER 10A
POT-SIG 22 17
ACCEL DIAL SIG 23 HEAD LAMP 20A
B/OR 18
FUEL LEVEL SENSOR 24 FUEL HEATER 30A
MONITORING CIRCUIT (CLUSTER TYPE 2)
TACHO SENSOR(-) 25
19
START,STOP 30A
TACHO SENSOR(+) 26 20
HORN 10A
NC 27 21
4-35
NC 28 AC& HEATER 20A
22
NC 29 SAFETY SOL 10A
NC 30 23
OPTION 20A
GND (SENSOR) 31 24
PUMP PROLIX SW SOLENOIDE 20A
32
25
WATER TEMP SENDOR 33 CIGAR 20A
BR/OR 26
HYD TEMP SENDOR 34 20A
OPTION(BEACON)
NC 35 27
TRAVEL SOL 20A
NC 36 28
PRE-HEAT 10A
29
FUEL P/P 20A
CN-50 30
BOOM PRIORITY SOL SPARE 10A
1
31
FUSE BOX
MAX FLOW SOL. 2

POWER MAX SOL. 3
HOUR-METER 4
ENG PREHEATER 5
FUEL HEATER 6
BATTERY 24V(+) 7
PUMP EPPR(-) 8
NC 9
PROGRAM DUMP 10
ANTI-RESTART RY 11
12
NC 27
GND (MAIN) 28
Y
SERIAL-TX 29
L
SERIAL-RX 30
GND 31
RS232 (+) 32
RS232 (-) 33
RS232 (GND) 34
3309S4EL22
NC 35
PUMP EPPR(+) 36
B
max
C
Horn
2
2
1
1
Brea
Decel
A
Power
SIG
SIG
SIG
2
1
2
1
CS-26A
C
1
2
CS-5
CD-2
CD-1
CS-29
ker CS-26
CS-19
-
+
S
HYD TEMP
L
L
B
B
A3
SUPPLY
R
R
BREAKER
SUPPLY
SUPPLY
Gr
Gr
RETURN
RETURN
RETURN
FUEL LEVEL
CD-24
A
B
C
SAFETY SW
A
B
A
SUPPLY
B
A
C
C
B
A
B
A
C
C
1
1
1
1
2
2
2
2
ACCEL DIAL
PUMP1 PRESS
PUMP2 PRESS
CS-4
CN-142
CD-44
CD-43
CD-42
SIG B
SWING
RETURN C
CD-31
SUPPLY A
SIG B
LOAD
OVER
RETURN C
CD-32
SUPPLY A
UP
SIG B
BOOM
RETURN C
CD-6
SUPPLY A
9
8
7
5
2
4
1
6
3
2
2
5
5
4
1
4
1
9
8
7
6
9
8
7
6
3
3
15
14
13
12
11
10
SIG B
16
15
14
13
12
11
10
16
15
14
13
12
11
10
CN-4
CN-7
CN-2
TRAVEL
RETURN C
CD-7
SUPPLY A
SIG B
WORK
RETURN C
CS-50
1
CN-76 2 12
2
M- 6
6 5 3
M M+ 5
NC 4 4
2
P- 3 5
3 1
SIG 2 6
GOV. MOTOR
P+ 1 3
7 7
9
8
OVERLOAD SW
4
9 8
10
10
11
11 12
12
ELECTRIC CIRCUIT FOR HYDRAULIC (CLUSTER TYPE 1)
CS-67
1
2 12
2
CN-51
BATT POWER_24V 1
3
POWER IG 2 4
POWER_24V OUT 3 5
TACHO SENSOR+ 4 6
GND_5V 5 3
7 7
POWER_5V OUT 6 9
8
G/A MOTOR(+) 7 4
G/A MOTOR(-) 8 9 8
10
nc 9 10
QUICK COUPLING SW
nc 10 11
11 12
GND_MAIN 11 12
CAN_SHIELD 12
CN-113
GND_RETURN 13
TACHO SENSOR- 15 2
PROGRAM DUMP 16
BUZZER
6
9
8
7
ONE TOUCH DECEL 17

10
12
60
59
58
57
35
34
33
32
31
30
29
28
27
11
CN-5
POWER BOOST SW 18
HOUR METER 19
ANTI RESTART RY 20
CAN1 Hi 21
CN-140
nc 22
2
1
RS232C1_TX-HRDT 24
RS232C2_TX-RCM 25
QUICK COUPLER SOL
ENG OIL PS 27
coolent level 28
AIR CLEANER SW(NO) 29
BLOWER SIG. 30
4-36
CAN1 Lo 31
nc 32 CN-36
RS485-(RX)-CLUSTER 33 IG POWER 30A
RS232C1_RX-HRDT 34 1
RS232C2_RX-RCM 35 2
PRE-HEAT SELECT SIG 36 MCU 30A
3
ENGINE OIL FILTER 37 30A
START KEY
nc 38 4
AIR CON/HEATER 20A
nc 39 5
nc 40 WIPER 10A
6
CLUSTER 10A
CN-52 7
MCU
ARM REGEN SOL CLUSTER 10A
1
8
POWER MAX SOL 2 MCU CONT. 20A
TRAVEL SPEED SOL 3 9
MCU_EPPR 20A
ATT_PRESS SOL. 5 SWITCH PANEL 10A
11
ATT_CONFLUX SOL. 6 CASSETTE 10A
BOOM PRIORITY EPPR+ 7 12
FUEL CUT-OFF SOL. 10A
POWER IG EPPR 8 13
PUMP POWER EPPR+ 9 CONVERTER 20A
14
ATT. EPPR+ 10 WORK LAMP 30A
nc 11 15
FUEL WARMER RY 12 16
TRAVEL BUZZER 13 WIPER 10A
17
ENG STOP RY 14 20A
HEAD LAMP
ENG PRE-HEAT RY 15 18
FUEL HEATER 30A
nc 16 19
BOOM PRIORITY EPPR- 17 START,STOP 30A
20
EPPR GND 18 10A
HORN
PUMP POWER EPPR- 19 21
AC& HEATER 20A
ATT. EPPR- 20 22
nc 21 SAFETY SOL 10A
nc
23
22 20A
OPTION
ACCEL DIAL SIG 23 24
SOLENOIDE 20A
HYD. TEMP SENDER 24 25
WATER TEMP SENDOR 25 CIGAR 20A
26
OPTION(BEACON) 20A
ALT. LEVEL 27 27
GOV. POTENTIO SIG. TRAVEL SOL 20A
28
28
P1 PRESS SENSOR 29 PRE-HEAT 10A
P2 PRESS SENSOR 30
29
FUEL P/P 20A
nc 31 30
PUMP EPPR2 SENSOR SPARE 10A
32
31
ATT PILOT PRESSURE
FUSE BOX
33
ARM IN_OUT BUCKET IN PRESS 34
BOOM UP PRESS SENSOR 35
SWING PRESS SENSOR 36
WORK PRESS SENSOR(A) 37
TRAVEL PRESS SENSOR(A) 38
OVERLOAD SIG 39
nc
2
5
4
1
9
8
7
6
3
40
12
11
10
CN-15
4
2
3
5
1
CR-62
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
1
2
1
2
CD-69
CN-66
CN-88
CN-70
CN-68
3 2
4 5 1
CN-242
CN-237
CN-149
CN-236
CN-135
CN-133
B SIG
BREAKER RY
POWER MAX
CN-81
TRAVEL BZ
TRAVEL-HIGH
SAFETY SOL
A SUPPLY
C RETURN
ATT
BOOM PRIORITY
ATT
ATT
ARM REGENERATION
ATT FLOW
ATT PS
PRESS SOL
SAFETY SOL
BREAKER SOL
CONFLUX SOL
3309S4EL23
P3 P1 P2
PRESS PRESS PRESS
SIG
SIG
SIG
max
C
Horn
2
2
1
1
Brea
Decel
A
Power
SUPPLY
SUPPLY
SUPPLY
RETURN
RETURN
RETURN
2
1
2
1
CS-26A
C
1
2
CS-5
CD-2
1
CD-1
2
B
A
B
A
CS-29
ker CS-26
C
C
CS-19
B
A
C
-
+
S
HYD TEMP
L
L
B
B
R
R
BREAKER
Gr
Gr
CD-44
CD-42
CD-43
FUEL LEVEL
CN-156
A
B
C
SAFETY SW
B
A
1
1
1
1
2
2
2
2
AIR SEAT
CS-4
ACCEL DIAL
CN-142
CD-31
PS
SUPPLY A
RETURN B
SIG C
CD-6
SUPPLY A
RETURN B
SIG C
6
5
4
1
2
2
2
5
5
4
1
4
1
9
8
7
6
9
8
7
6
3
3
16
15
14
13
12
11
10
16
15
14
13
12
11
10
CN-4
CN-7
CD-7
CN-1
SUPPLY A
RETURN B
CS-27
SIG C
OVERLOAD TRAVEL WORK

1
2 12
2
CN-76
M- 6
3
6 5
4
9
8
7
5
2
4
1
6
3
M+ 5
15
14
13
12
11
10
M
CN-2
NC 4 5
2
P- 3 6
3 1
SIG 2 3
7 7
P+ 1 9
GOV. MOTOR
8
4
BREAKER SW
9 8
10
10
11
11 12
12
CS-50
1
2 12
2
3
4
5
ELECTRIC CIRCUIT FOR HYDRAULIC (CLUSTER TYPE 2)
6
3
7 7
9
8
4
OVERLOAD SW
9 8
10
10
11
11 12
12
CS-67
1
2 12
2
CN-51
WORKING PS 1
3
POWER MAX SW 2 4
TRAVEL ALARM SW 3 5
ENG OIL PS 4 6
NC 5 3
7 7
NC 6 9
8
24V(PRES.SENSOR) 7 4
GND(PRES.SENSOR) 8 9 8
10
ALT LEVEL 9 10
QUICK COUPLING SW
P1 PRESS SIG. 10 11
P2 PRESS SIG.
11 12
11 12
P3 PRESS SIG. 12
CN-113
TRAVEL PS 13
O/T DECEL SW 14 1
WATER LEVEL SW 15 2
AIR CLEANER SW 16
BUZZER
6
9
8
7
NC 17
10
12
60
59
54
53
35
34
33
32
31
30
29
28
27
11
CN-5
NC 18
NC 19
GND (POT&DIAL) 20
5V (POT&DIAL) 21
4-37
CN-140
POT-SIG 22
2
ACCEL DIAL SIG 23
1
TACHO SENSOR(-) 25
TACHO SENSOR(+) 26
QUICK COUPLER SOL
NC 27
NC 28
NC 29
NC 30
GND (SENSOR) 31
PUMP PROLIX SW 32 CN-36
WATER TEMP SENDOR 33 30A
IG POWER
HYD TEMP SENDOR 34 1
NC 35 2
NC 36 MCU 30A
3
START KEY 30A
CN-50 4
MCU
BOOM PRIORITY SOL 1 AIR CON/HEATER 20A
MAX FLOW SOL. 2
5
WIPER 10A
POWER MAX SOL. 3 6
HOUR-METER SPARE 10A
4
7
ENG PREHEATER 5 CLUSTER 10A
FUEL HEATER 6 8
MCU CONT. 20A
BATTERY 24V(+) 7 9
PUMP EPPR(-) 8 FUEL CUT OFF 10A
10
NC 9 SWITCH PANEL 10A
PROGRAM DUMP 10 11
CASSETTE 10A
ANTI-RESTART RY 11 12
ACCEL ACT(+) 12 SPARE 30A
13
TRAVEL SPEED SOL. 13 CONVERTER 20A
NC 14 14
WORK LAMP 30A
NC 15 15
TRAVEL BUZZER 16 CABIN LAMP(OPTION) 30A
16
PRE-HEAT SW 17 10A
WIPER
NC 18 17
HEAD LAMP 20A
NC 19 18
OVERLOAD SIG 20 FUEL HEATER 30A
ENGINE OIL FILTER
19
21 START,STOP 30A
HOUR-METER 22 20
HORN 10A
ACCEL ACT(-) 23 21
POWER IG 24 AC& HEATER 20A
NC
22
25 10A
SAFETY SOL
NC 26 23
OPTION 20A
NC 27 24
GND (MAIN) 28 SOLENOIDE 20A
SERIAL-TX 29
25
CIGAR 20A
SERIAL-RX 30 26
GND OPTION(BEACON) 20A
31
27
RS232 (+) 32 TRAVEL SOL 20A
RS232 (-) 33
28
PRE-HEAT 10A
RS232 (GND)
9
8
7
5
2
4
1
34
6
3
29
12
11
10
FUEL P/P 20A

CN-3
NC 35
30
PUMP EPPR(+) 36 SPARE 10A
31
FUSE BOX
4
2
3
5
1
CR-62
1
1
1
2
2
2
2
1
2
2
1
1
2
CD-8
CN-88
CN-70
CN-66
CN-68
C
3 2
4 5 1
CN-133
BREAKER RY
POWER MAX
CN-81
TRAVEL BZ
TRAVEL-HIGH
SAFETY SOL
BREAKER SOL
BOOM PRIORITY
WATER TEMP SENDOR
3309S4EL24
GROUP 3 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check
※ Check specific gravity

12V × 100Ah 1.280 over : Over charged
Battery
(2EA) 1.280 ~ 1.250 : Normal
1.250 below : Recharging
Rated load : ※ Check coil resistance(M4 to M4)

24V Normal : About 50Ω
Battery relay
100A (continuity) ※ Check contact
1000A (30seconds) Normal : ∞Ω
CR-1
※ Check contact
Pre-heat relay 24V 200A Normal : 0.942Ω
(For terminal 1-GND)
CR-24
5
4
1
6
2
3
B
※ Check contact
0, I
B-BR : 24V 1A OFF : ∞Ω(for each terminal)
1
Start key B-ACC : 24V 10A

ON : 0Ω(for terminal 1-3 and 1-2)
H0 I B-ST : 24V 40A
4
3
2
6
5
STC BR ACC H
START : 0Ω(for terminal 1-5)
CS-2
A SUPPLY
B SIG
Pressure
sensor C RETURN 8~30V ※ Check contact
(cluster type 1) CD-7 CD-7 CD-24 Normal : 0.1Ω
CD-6
CD-31 CD-32 CD-42
CD-43 CD-44 CD-69
A SUPPLY
B SIG
Pressure
C RETURN 8~30V ※ Check contact
sensor
(cluster type 2) CD-7 CD-7 CD-31 Normal : 0.1Ω
CD-6
CD-42 CD-43 CD-44
4-38
Pre-heat plug 24V 200A ※ Check resistance

0.25~0.12Ω
CN-80
C 1 ※ Check resistance
Temperature
- 50˚C : 804Ω
sensor
2 80˚C : 310Ω
(hydraulic,
coolant) CD-8 100˚C : 180Ω
CD-1 CD-8
※ Check contact
Air cleaner Pa High level : ∞Ω
pressure switch (N.O TYPE)
Low level : 0Ω
CD-10
※ Check resistance
Full : 50Ω 6/12 : 350Ω
2 11/12 : 100Ω 5/12 : 400Ω
10/12 : 150Ω 4/12 : 450Ω
Fuel sender 1 - 9/12 : 200Ω 3/12 : 500Ω
8/12 : 250Ω 2/12 : 550Ω
CD-2 7/12 : 300Ω 1/12 : 600Ω
Empty warning : 700Ω
3 4 4 ※ Check resistance
3 Normal : About 200Ω
Relay
(air con blower)
2 24V 20A (for terminal 1-3)
1 2 1 0Ω
CR-46 (for terminal 2-4)
1
2
4 5 1 ※ Check resistance
3 Normal : About 160 Ω
Relay (for terminal 1-2)
4 24V 16A
3 2
5 0Ω(for terminal 3-4)
CR-2
CR-2 CR-36
CR-5 CR-62
CR-36 ∞Ω(for terminal 3-5)
CR-45
Cluster CR-62
type 2 only (CR-52)
4-39
30
87a 87 85 ※ Check resistance
86
87
Normal : About 160 Ω
Relay 85 24V 16A (for terminal 85-86)
87a 30 86
0Ω(for terminal 30-87a)
CR-4
CR-4 CR-7CR-7
CR-5 CR-9CR-9
CR-13 CR-35 CR-46 ∞Ω(for terminal 30-87)
CR-13 CR-35 CR-46
1 ※ Check resistance
Solenoid valve
24V 1A Normal : 15~25Ω
(cluster type 1) 2
(for terminal 1-2)
CN-66 CN-68 CN-70
CN-88 CN-135 CN-140
CN-149 CN-236 CN-237
1
Solenoid valve
2 24V 1A Normal : 15~25Ω
(cluster type 2)
CN-66 CN-68 CN-70
CN-70 (for terminal 1-2)
CN-66 CN-68
CN-88 CN-135 CN-140
CN-88 CN-140 CN-133
CN-149 CN-236 CN-237
1 ※ Check resistance
EPPR valve Normal : 15~25Ω
2 700mA
(cluster type 1)
(for terminal 1-2)
CN-75
CN-75 CN-133
CN-133 CN-242
CN-238
CN-239 CN-240 CN-241
CN-242
1
Speaker 2
20W
Normal : A fewΩ
CN-23(LH)
CN-24(RH)
※ Check contact
7
6
3
2
1
8
4
12
5
11
10
11
2
8
Normal
Switch
24V 8A ON : 0 Ω(for terminal 3-7, 4-8)
(locking type)
∞Ω(for terminal 7-9, 8-10)
10
12
12
9
4
OFF : ∞Ω(for terminal 3-7, 4-8)

CS-23
CS-23 CS-50
CS-50CS-52
CS-67CS-67
CS-82 0 Ω(for terminal 7-9, 8-10)
CS-83 CS-83
CS-82 CS-99CS-99
CS-100
CS-100
※ Check resist
Normal : About 5kΩ
A + (for terminal A-C)
B S ※ Check voltage
Accel dial -
C - Normal : About 5V
(for terminal A-C)
CN-142 : 2~4.5V
(for terminal C-B)
4-40
3 ※ Check disconnection
Normal : 1.0Ω
2 ON : 0Ω(For terminal 1-2)
Room lamp 24V 10W ∞Ω(For terminal 1-3)
1
OFF : ∞Ω(For terminal 1-2)
CL-1 0Ω(For terminal 1-3)
2
Head lamp, 24V 65W ※ Check disconnection
Work lamp, 1
(H3 Type) Normal : 1.2Ω
Cab lamp CL-3 CL-4
CL-4 CL-5 CL-5
CL-6
CL-8 CL-9 CL-9
CL-6 CL-8
Beacon lamp 21V 70W ※Check disconnection

M (H1 Type) Normal : A fewΩ
CL-7
-
CL-7
1 M
24V 10A ※Check resistance
Fuel filler pump 2 35ℓ /min Normal : 1.0Ω
CN-61
3 ※Check operation
2
h Supply power(24V) to terminal
Hour meter 16~32V
1 No.2 and connect terminal No.1
CN-48 and ground
1 ※Check operation
Horn DC22~28V Supply power(24V) to each
2 2A terminal and connect ground.
CN-20 CN-25
4-41
※Check contact
2 3 1
Normal : 0Ω(for terminal 1-2)
24V 15A
Safety switch 2 ∞Ω(for terminal 1-3)
(N.C TYPE)
Operating : ∞Ω(for terminal 1-2)
3
1 0Ω(for terminal 1-3)
CS-4
CS-4
24V ※Check contact

Wiper cut switch (N.O TYPE) Normal : 0Ω(one pin to ground)
CS-53
1
Receiver dryer P ※Check contact
2 24V 2.5A Normal : ∞Ω
CN-29
CN-29
10
11
12
13
14
15
16
1
2
3
4
5
6
7
9
8
Radio & ※Check voltage

REMOCON GND
SPK FRT RH+
SPK FRT LH+

SPK FRT RH-
24V 2A
SPK FRT LH-
REMOCON+
USB plalyer 20~25V

BACK UP+
TEL MUTE
ANT 12V
GND
GND
(for terminal 1-3, 3-8)

ACC
ILL+
ILL-
NC
NC
CN-27
Washer pump 24V 3.8A ※Check contact

Normal : 10.7Ω(for terminal 1-2)
CN-22
3 1
2
5 3
4 ※Check disconnection
Wiper motor 4
24V 2A
5
Normal : 7Ω(for terminal 2-6)
6 M 2 6
CN-21
4-42
3 12V 12V
DC/DC 2 24V 24V (1-2)
Converter 1 GND 24V 12V 3A
12V (1-3)
CN-138
※Check coil resistance

Normal : About 1MΩ
Cigar lighter 24V 5A 1.4W ※Check contact
Normal : ∞Ω
Operating time : 5~15sec
CL-2
CL-2
B+
G
1 P
3 ~
2 L
U Delco Remy ※Check contact
Normal : 0Ω (for terminal B+-I)
3 FI
Alternator 4 NC 24V 50A
CN-74 Normal : 24~27.5V
M
M
Starter Denso ※Check contact
24V 4.5kW Normal : 0.1Ω
B+
CN-45
Travel alarm ※Check contact

24V 0.5A
Normal : 5.2Ω
CN-81
1
Aircon ※Check contact
compressor 24V 79W Normal : 13.4Ω
CN-28
4-43
Start relay ※Check contact

24V 300A
Normal : 0.94Ω(for terminal 1-2)
CR-23
1 M ※Check resistance
Blower motor 24V 9.5A
2 Normal : 2.5Ω(for terminal 1-2)
※Check resistance
Duct sensor 2 1˚C OFF Normal : 0Ω(for terminal 1-2),
(switch) 4˚C ON the atmosphere temp :
1
Over 4˚C
Door switch 24V 2W ※Check resistance

Normal : About 5MΩ
CS-1
CS-1
Switch 1
(power max, ※Check resistance
24V 6A
one touch decel, 2 Normal : ∞Ω
horn, breaker)
CS-5 CS-19
CS-26 CS-26A CS-29
2 ※Check disconnection
normal : 0Ω
Fusible link 60A
1 (connect ring terminal and check
resist between terminal 1 and 2)
CN-60 CN-95
4-44
Master switch 6-36V ※Check disconnection

Normal : 0.1Ω
CS-74 CS-74B
2 ※Check resistance
m
rp
Speed sensor - Normal : 300Ω

1
(for terminal 1.2)
CD-17
Pressure ※Check resistance

Pa 0.5 kgf·m2
switch
(N.C TYPE) Normal : ∞Ω(CLOSE)
(engine oil)
CD-18
M- 6
6 5
M M+ 5 ※Check resistance
NC 4
2 Normal : 1~2Ω(for terminal 5-6)
Accel actuator 3 1
P- 3
-
SIG 2 0.8~1.2Ω
P+ 1
(for terminal 1-3)
CN-76
1
24V 200mA
Travel alarm 2 107 ± 4dB
-
CN-113
1
Socket 2
12V 10A -
CN-139
4-45
GROUP 4 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 AMP 6 I/conn (Frame harness-Pump PS harness cluster type 2) S816-006002 S816-106002
CN-2 AMP 15 I/conn (Frame harness-Engine harness) 2-85262-1 368301-1
CN-3 AMP 12 I/conn (Frame harness-Engine harness) S816-012002 S816-112002
CN-4 AMP 16 I/conn (Console harness LH-Frame harness) 368047-1 S816-112002
CN-5 DEUTSCH 60 I/conn (Side harness RH-Frame harness) DRB16-60SAE-L018 DRB12-60PAE-L018
CN-7 AMP 16 I/conn (Console harness RH-Frame harness) 368047-1 S816-116002
CN-8 AMP 12 I/conn (Console harness RH-Frame harness) S816-012002 S816-112002
CN-10 DEUTSCH 12 I/conn (Cab harness-Side harness RH) DT06-12S-EP06 DT04-12P-BE02
CN-11 DEUTSCH 8 I/conn (Frame harness-Aircon harness) DT06-8S-EP06 -
CN-12 DEUTSCH 2 I/conn (Frame harness-Boom wire harness) DT06-2S-EP06 DT04-2P-E005
CN-15 AMP 12 I/conn (Frame harness-Breaker solenoid) S816-012002 S816-112002
CN-17 AMP 8 I/conn (Wiper harness-Side harness RH) S816-008002 S816-108002
CN-20 MOLEX 2 Horn 36825-0211 -
CN-21 AMP 6 Wiper motor 925276-0 -
CN-22 KET 2 Washer pump MG640605 -
CN-23 KET 2 Speaker-LH MG610070 -
CN-24 KET 2 Speaker-RH MG610070 -
CN-25 MOLEX 2 Horn 36825-0211 -
CN-27 KUM 16 Radio & USB player PK145-16017 -
CN-28 KUM 1 Aircon compressor MWP-01F-B -
CN-29 KET 2 Receiver dryer MG640795 -
CN-36 - - Fuse & relay box 21Q7-10910 -
CN-45 RING-TERM - Starter motor B+ S820-308000 -
CN-48 KET 1 Hour meter 2-520193-2 -
CN-51 AMP 36 MCU 341111-1 -
CN-52 AMP 36 MCU 341111-1 -
CN-56 AMP 8 Cluster (type 1) - S816-108002
CN-56 DEUTSCH 4 Cluster (type 2) - DT04-4P
CN-60 AMP 2 Fusible link - S813-130201
CN-61 DEUTSCH 2 Fuel filler pump DT06-2S-EP06 -
CN-66 DEUTSCH 2 Breaker solenoid DT06-2S-EP06 DT04-2P-E005
CN-68 DEUTSCH 2 Safety solenoid DT06-2S-EP06 -
CN-70 DEUTSCH 2 Travel high solenoid DT06-2S-EP06 -
CN-74 AMP 4 Alternator "l" terminal 12186568 -
4-46
Type Destination
CN-75 AMP 2 Pump EPPR S816-002002 -
CN-76 DEUTSCH 6 Accel actuator DT06-6S-EP06 -
CN-79 AMP 3 Fuel cut off solenoid 12124685
CN-80 RING-TERM - Glow plug S820-306000 -
CN-81 DEUTSCH 2 Travel buzzer solenoid DT06-2S-EP06 -
CN-88 DEUTSCH 2 Power max solenoid DT06-2S-EP06 -
CN-95 AMP 2 Fusible link - S813-130201
CN-96 AMP 4 Fuel warmer 2-967325-3 -
CN-113 KET 2 Buzzer MG651205-5 -
CN-116 AMP 12 Switch panel 176116 -
CN-125A Econoseal J 4 GPS connector (cluster type 1) DT06-12S -
CN-126 AMP 8 Service tool S816-010002 -
CN-133 DEUTSCH 2 Boom priority solenoid DT06-2S-EP06 -
CN-135 DEUTSCH 2 Arm regeneration solenoid (cluster type 1) DT06-2S-EP06 -
CN-138 DEUTSCH 3 DC/DC Converter DT06-3S -
CN-139 FASTEN 2 12V socket 170434-2 -
CN-140 DEUTSCH 2 Quick clamp solenoid DT06-2S-EP06 DT04-2P-E005
CN-141 AMP 13 Wiper motor controller 172498-1 DT04-3P-EP10
CN-142 DEUTSCH 3 Accel dial DT06-3S-EP06 -
CN-147 AMP 4 Fuel-heater 2-967325-3 -
CN-149 DEUTSCH 2 Attach safety solenoid (cluster type 1) DT06-2S-EP06 -
CN-156 DEUTSCH 2 Air seat DT04-2P-E005 -
CN-157 AMP 1 Antena power S822-014002 -
CN-170 AMP 2 Heated seat 12052641 12162000
CN-236 DEUTSCH 2 Attach pressure solenoid (cluster type 1) DT06-2S-EP06 -
CN-237 DEUTSCH 2 Attach conflux solenoid (cluster type 1) DT06-2S-EP06 -
CN-242 AMP 2 Attach flow solenoid (cluster type 1) DT06-2S-EP06 DT04-2P-E005
CN-246 AMP 10 USB 316988-6 -
CN-249 AMP 4 Rear view camera (cluster type 1) S816-004002 S816-104002
·Relay
CR-1 RING-TERM - Battery relay ST710285-2 -
CR-2 - 5 Horn relay - -
CR-4 - 5 Working lamp relay - -
CR-5 - 5 Anti restart relay - -
CR-7 - 5 Aircon compressor relay - -
CR-9 - 5 Head lamp relay - -
CR-13 - 5 Cabin lamp relay - -
CR-23 AMP 2 Start relay - 814-102001
CR-24 RING TERM 1 Preheat relay S822-014000 -
4-47
Type Destination
CR-35 - 5 Power relay - -
CR-36 - 5 Preheat relay - -
CR-46 - 5 Fuel warmer relay - -
CR-62 - 5 Breaker relay - -
·Switch
CS-1 SHUR 1 Door switch S822-014002 S822-114002
CS-2 WP 6 Start key switch S814-006100 -
CS-4 DEUTSCH 3 Safety switch DT06-3S-EP06 -
CS-5 DEUTSCH 2 Horn switch - DT04-2P-E005
CS-19 DEUTSCH 2 One touch decel switch - DT04-2P-E005
CS-20 AMP 1 Safety switch S822-014002 -
CS-23 SWF 12 Beacon lamp switch SWF589790 -
CS-26 DEUTSCH 2 Breaker switch DT06-2S-EP06 -
CS-26A AMP 2 Breaker pedal switch S816-002002 S816-102002
CS-27 SWF 10 Breaker switch (cluster type 2) SWF 593757 -
CS-29 DEUTSCH 2 Power max switch DT06-2S-EP06 -
CS-50 SWF 12 Overload switch SWF589790 -
CS-53 AMP 1 Wiper cut switch S822-014002 -
CS-67 SWF 12 Quick clamp switch SWF 589790 -
CS-73 SWF 12 Spare switch SWF 589790 -
CS-74A AMP 2 Master switch S813-030201 -
CS-74B DEUTSCH 2 Master switch DT06-2S-EP06 -
CS-142 DEUTSCH 3 Accel dial LED DT06-3S-EP06 -
·Light
CL-1 KET 3 Room lamp MG651032 -
CL-2 AMP 1 Cigar light S822-014002 S822-114002
CL-3 DEUTSCH 2 Head lamp-LH DT06-2S-EP06 -
CL-4 DEUTSCH 2 Head lamp-RH DT06-2S-EP06 DT04-2P-E005
CL-5 DEUTSCH 2 Work lamp-LH - DT04-2P
CL-6 DEUTSCH 2 Work lamp-RH - DT04-2P
CL-7 SHUR 1 Beacon lamp S822-014002 S822-114002
CL-8 DEUTSCH 2 Cab light-LH DT06-2S-EP06 DT04-2P-E005
CL-9 DEUTSCH 2 Cab light-RH DT06-2S-EP06 DT04-2P-E005
4-48
Type Destination
·Sensor, sendor
CD-1 AMP 2 Hydraulic oil temp sender 85202-1 -
CD-2 DEUTSCH 2 Fuel sender DT06-2S-EP06 -
CD-6 DEUTSCH 3 Travel pressure switch DT06-3S-EP06 -
CD-7 DEUTSCH 3 Working pressure switch DT06-3S-EP06 -
CD-8 AMP 2 Coolant temp sender 85202-1 -
CD-10 RING TERM - Air cleaner switch ST730135-2 S820-104000
CD-17 AMP 2 Speed sensor - S818-120221
CD-18 RING TERM - Engine oil pressure switch S820-104000 -
CD-24 DEUTSCH 3 Swing sensor (cluster type 1) DT06-3S-EP06 -
CD-31 AMP 3 Overload sensor S816-003002 S816-103002
CD-32 DEUTSCH 3 Boom up sensor (cluster type 1) DT06-3S-EP06 -
CD-42 AMP 3 Pump pressure 1 S816-004002 -
CD-43 AMP 3 Pump pressure 2 S816-004002 -
CD-44 DEUTSCH 3 Pump pressure 3 DT06-3S-EP06 -
CD-69 DEUTSCH 3 Attach pressure sensor (cluster type 1) DT06-3S-EP06 -
4-49
2. CONNECTION TABLE FOR CONNECTORS
1) PA TYPE CONNECTOR
No. of
pin Receptacle connector (female) Plug connector (male)
2 5 1 3
1 3 2 5
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9 1 5
1 5 4 9
S811-009002 3S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
4 - 50
No. of
Receptacle connector (female) Plug connector (male)
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
8 1 9
17
17
1 9 8 17
S811-017002 S811-117002
1 21
1 11
21
1 11 1 21
S811-021002 S811-121002
4 - 51
2) J TYPE CONNECTOR
No. of
pin
1 1
2
2 12
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
3 1 4 2
4 2 3 1
S816-004001 S816-104001
8 5 2
6 3 1
8 5 2 6 3 1
S816-008001 S816-108001
4 - 52
3) SWP TYPE CONNECTOR
No. of
pin
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4
1 3
1 3 2 4
S814-004000 S814-104000
4 - 53
No. of
pin Receptacle connector (female) Plug connector (male)
3 6
1 4
1 4 3 6
S814-006000 S814-106000
4 8
1 5
1 5 4 8
S814-008000 S814-108000
4 12
1 9
12
4 12
1 9
S814-012000 S814-112000
3 14
1 11
14
1 11 3 14
S814-014000 S814-114000
4 - 54
4) CN TYPE CONNECTOR
No. of
pin
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 3
1 3 2 4
S810-004202 S810-104202
4 - 55
No. of
pin
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
4 - 56
5) 375 FASTEN TYPE CONNECTOR
No. of
pin
1 2 1 2
S810-002402 S810-102402
6) AMP ECONOSEAL CONNECTOR

No. of
pin
12
1
1 13
24
36
36 25
13 12
24
25 36
344111-1 344108-1
7) AMP TIMER CONNECTOR

No. of
pin
85202-1
4 - 57
8) AMP 040 MULTILOCK CONNECTOR
No. of
pin
12 1 6
7 12
174045-2
9) AMP 070 MULTILOCK CONNECTOR

No. of
pin
1 6
14
7 14
173852
10) AMP FASTIN - FASTON CONNECTOR

No. of
pin
3 1
6
6 4
1
4 6 3
480003-9
925276-0
4 - 58
11) KET 090 CONNECTOR
No. of
pin
1
2
MG610070
12) KET 090 WP CONNECTORS

No. of
pin
1
2
MG640605
2 1
MG640795
4 - 59
13) KET SDL CONNECTOR
No. of
pin
14
7
6
14
MG610406
4 - 60
14) DEUTSCH DT CONNECTORS
DT 06 - 3S - ★★★★
Modifications (see below)

Number of contacts (P : Pin, S : Socket)
04 : Receptacle, 06 : Plug
Deutsch connectors
※ Modification
E003 : Standard end cap - gray
E004 : Color of connector to be black
E005 : Combination - E004 & E003
EP04 : End cap
EP06 : Combination P012 & EP04
P012 : Front seal enhancement - connectors color to black for 2, 3, 4 & 6pin
No. of
pin
1 2 2 1
2
DT06-2S DT04-2P
2 1 1 2
3 3
DT06-3S DT04-3P
4 1 1 4
3 2 2 3
DT06-4S DT04-4P
4 - 61
No. of
pin
6 1 1 6
4 3 3 4
DT06-6S DT04-6P
4 5 5 4
1 8
8 1
DT06-8S DT04-8P
7 6
6 7
12
1 12 12 1
DT06-12S DT04-12P
4 - 62
15) MOLEX 2CKTS CONNECTOR
No. of
pin
1 2
35215-0200
35215-0200
16) ITT SWF CONNECTOR

No. of
pin
2
10
1 10
SWF593757
17) MWP NMWP CONNECTOR

No. of
pin
1
1
NMWP01F-B
4 - 63
18) ECONOSEAL J TYPE CONNECTORS
No. of
pin
S816-001002 S816-101002
1 2 2 1
S816-002002 S816-102002
S816-003002 S816-103002
S816-004002 S816-104002
4 - 64
No. of
pin
S816-006002 S816-106002
S816-008002 S816-108002
10
S816-010002 S816-110002
12
S816-012002 S816-112002
4 - 65
No. of
pin
15
368301-1 2-85262-1
19) METRI-PACK TYPE CONNECTOR

No. of
pin
12040753
20) DEUTSCH HD30 CONNECTOR

No. of
pin
J K
K J
B
23 N T
A B
F
F Q N
Q A
HD36-24-23SN HD34-24-23PN
4 - 66
21) DEUTSCH MCU CONNECTOR
No. of
Receptacle connector (Female) Plug connector (Male)
pin
5
1 6
11 1
10
2
3
11 4
5
21
6
40 21 31
32
7
8
9
33 10
34
35
31 36
37
20
30
20
38
39
35 40
36
30
40
DRC26-40SA/B/C
22) DEUTSCH SERVICE TOOL CONNECTOR

No. of
pin
C
D
E
A
9
F
B
G
H J
HD10-9-96P
23) AMP FUEL WARMER CONNECTOR

No. of
pin
3 2
2-967325-3
4 - 67
24) DEUTSCH E
ENGINE
NGINE ECM CONNECTOR
No. of
pin
1 5
6
11
1
10
2
11 3
4
21 5
21 31
6
7
50 31 41
42
8
9
10 20
43
44
41 45
20
46
47
30
40
30
48
45 49
50
46
50 40
DRC26-50S-04
25) DEUTSCH INTERMEDIATE CONNECTOR

No. of
pin
1
13 12
25 24
31
30
60 37
36
49
48
60
DRB16-60SAE-L018
4 - 68
Group 1 Outline----------------------------------------------------------------------------------------------------------------- 5-1

Group 2 Mode Selection System ------------------------------------------------------------------------------------ 5-5
Group 3 Automatic Deceleration System ----------------------------------------------------------------------- 5-11
Group 4 Power Boost System ----------------------------------------------------------------------------------------- 5-13
Group 5 Travel Speed Control System --------------------------------------------------------------------------- 5-15
Group 6 Automatic Warming Up System ----------------------------------------------------------------------- 5-17
Group 7 Engine Overheat Prevention System --------------------------------------------------------------- 5-19
Group 8 Variable Power Control System ------------------------------------------------------------------------ 5-21
Group 9 Attachment Flow Control System --------------------------------------------------------------------- 5-22
Group 10 Anti-Restart System ------------------------------------------------------------------------------------------- 5-23
Group 11 Self-Diagnostic System ------------------------------------------------------------------------------------- 5-24
Group 12 Engine Control System ------------------------------------------------------------------------------------- 5-31
Group 13 EPPR Valve -------------------------------------------------------------------------------------------------------- 5-33
Group 14 Monitoring System --------------------------------------------------------------------------------------------- 5-39
Group 15 Fuel Warmer System ----------------------------------------------------------------------------------------- 5-71
GROUP 1 OUTLINE (CLUSTER TYPE 1)
The CAPO (Computer Aided Power Optimization) system controls engine and pump mutual power at
an optimum and less fuel consuming state for the selected work by mode selection, auto-deceleration,
power boost function, etc. It monitors machine conditions, for instance, engine speed, coolant
temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
It consists of a MCU, a cluster, an accel actuator, EPPR valves, and other components. The MCU and
the cluster protect themselves from over-current and high voltage input, and diagnose malfunctions
caused by short or open circuit in electric system, and display error codes on the cluster.
Power mode selection (P, S, E)

Mode selection system Work mode selection
User mode system (U)
Auto deceleration system
Power boost system
Travel speed control system
Automatic warming up system
Engine overheat prevention system

NEW CAPO
SYSTEM
Variable power control system
Attachment flow control system
Anti-restart system
MCU & cluster protection
Self-diagnostic system Open-short diagnosis & error code display
Machine error code display
Machine condition monitoring
Machine monitoring system
Electric signal monitoring
One touch deceleration system
5-1
SYSTEM DIAGRAM (CLUSTER TYPE 1)
Work tool Attachment pilot Work Travel

pressure pressure pressure
MCV
Arm 1 Arm 2
SOLENOID VALVE EPPR VALVE

Option Bucket
Travel speed Attachment

pressure Boom 2 Boom 1
Power boost Attachment Travel(LH) Boom priority

conflux Swing
EPPR
Arm regen Attachment Travel(RH) Attachment

safety flow EPPR
Overload P1
pressure pressure
sensor
P2
pressure
Boom cylinder
Engine Main pump
Coolant
temp sensor P1 P2
P3
Pilot pump
Pump power
shift EPPR
Signal
Coolant temperature signal Pressure signal

Pressure signal
Drive signal
MCU
Drive signal Pressure signal
Switch signal
Pressure signal Accel dial signal CN-16A CN-16
Power boost
One touch button Normal
decel button Horn button CN-16B
Emergency
Option
button
LH control RH control Accel dial
lever lever
Serial communication(-)
Serial communication(+)
SL SR AO AI BI BU
Shuttle
block
Swing Boom up
pressure pressure Cluster
3309S5MS01
5-2
■ OUTLINE (CLUSTER TYPE 2)
The NEW CAPO (Computer Aided Power Optimization) system controls engine and pump mutual
power at an optimum and less fuel consuming state for the selected work by mode selection, auto-
deceleration, power boost function, etc. It monitors machine conditions, for instance, engine speed,
coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
It consists of a MCU, a cluster, an accel actuator, EPPR valves, and other components. The MCU and
the cluster protect themselves from over-current and high voltage input, and diagnose malfunctions
caused by short or open circuit in electric system, and display error codes on the cluster.
Engine control system

Mode selection system Pump control system
Work mode selection
User mode system (M, U)
Auto deceleration system
Power boost system
Travel speed control system
Automatic warming up system
Engine overheat prevention system

NEW CAPO
SYSTEM
Anti-restart system
MCU & cluster protection
Self-diagnostic system Open-short diagnosis & error code display
Machine error fault code display
Machine condition monitoring
Machine monitoring system
Electric signal monitoring
One touch deceleration system
5-3
SYSTEM DIAGRAM (CLUSTER TYPE 2)
Work Travel
pressure pressure
MCV
Arm 1 Arm 2
SOLENOID VALVE EPPR VALVE
Option Bucket
Travel speed Boom 1

Boom 2
Power boost Swing Travel(LH)
Arm regen Travel(RH) Boom priority

EPPR
Overload P1
pressure pressure
sensor
P2
pressure
Boom cylinder
Engine
Main pump
Coolant
temp sensor P1 P2
P3
Pilot pump
Pump power
shift EPPR
Signal
Coolant temperature signal Pressure signal

Pressure signal
Drive signal
MCU
Drive signal Pressure signal
Signal
Accel dial signal CN-16A CN-16
Power boost
One touch button Normal
decel button Horn button CN-16B
Emergency
Option
button
LH control RH control Accel dial
lever lever
Serial communication(-)
Serial communication(+)
Cluster
3309S5MS20A
5-4
GROUP 2 MODE SELECTION SYSTEM (CLUSTER TYPE 1)
1. POWER MODE SELECTION SYSTEM
Main control valve
Engine
P1 P2
Main pump Pilot pump
Pump shift
EPPR
Cluster
Drive signal
MCU
Normal
CN-16B
Emergency
Power mode Accel dial

pilot lamp
Power mode switch signal
3009SH5MS02
Mode selection system (micro computer based electro-hydraulic pump and engine mutual control
system) optimizes the engine and pump performance.
The combination of 3 power modes (P, S, E) and accel dial position (10 set) makes it possible to use
the engine and pump power more effectively corresponding to the work conditions from a heavy and
great power requesting work to a light and precise work.
Engine rpm Power shift by EPPR valve
Power Standard Option Standard Option
Application
mode
Current Pressure Current Pressure
Unload Load Unload Load
(mA) (kgf/cm2) (mA) (kgf/cm2)
P Heavy duty power 2100±50 1900±50 2100±50 1900±50 360±30 12±3 280±30 7
S Standard power 2000±50 1800±50 2050±50 1850±50 360±30 12±3 280±30 7
E Economy operation 1900±50 1700±50 1950±50 1750±50 360±30 12±3 360±30 12±3
AUTO Engine
1150±100 - 1150±100 - 700±30 38±3 700±30 38±3
DECEL deceleration
One touch Engine quick
1000±100 - 1000±100 - 700±30 38±3 700±30 38±3
decel deceleration
KEY Key switch
1000±100 - 1000±100 - 700±30 38±3 700±30 38±3
START start position
※ Power shift (Standard/Option) can be changed by "Service menu" in "Management" on the cluster.
5-5
2. WORK MODE SELECTION SYSTEM
Work mode consists of the general operation (bucket) and the optional attachment (breaker,
crusher).
Attachment pilot
pressure sensor
Main control valve
Work tool
Arm 1 Arm 2
SOLENOID VALVE
Option Bucket
Attachment
pressure
Boom 2 Boom 1
Attachment
conflux
Swing Travel(LH)
Attachment
Travel(RH) safety
Engine

Pump power
shift EPPR
Cluster
Drive signal
Drive signal
MCU
Pressure signal
Normal
CN-16B
Emergency
Work mode Work mode switch signal
pilot lamp
Accel dial
3309S5MS03
1) GENERAL WORK MODE (bucket)

This mode is used to general digging work.
2) ATT WORK MODE (breaker, crusher)
It controls the pump flow and system pressure according to the operation of breaker or crusher.
General mode Work tool

Description
Bucket Breaker Crusher
Attachment safety solenoid OFF ON ON
Attachment pressure solenoid OFF OFF ON
Attachment conflux solenoid OFF OFF ON/OFF
Attachment flow EPPR current 100 mA 100~700 mA 0~700 mA
5-6
3. USER MODE SELECTION SYSTEM
Main control valve
Engine

Pump power
shift EPPR
Drive signal
Cluster
MCU
Normal
CN-16B
Emergency
User mode Accel dial

pilot lamp
User mode switch signal
3009SH5MS04
1) High idle rpm, auto idle rpm and EPPR pressure can be adjusted and memorized in the U-mode.
2) LCD segment vs parameter setting
Step Engine speed Idle speed Power shift
( ) (rpm) (rpm) (bar)
1 1500 1000 (low idle) 0
2 1600 1050 3
3 1700 1100 6
4 1800 1150 (decel rpm) 9
5 1850 1200 12
6 1900 1250 16
7 1950 1300 20
8 2000 1350 26
9 2050 1400 32
10 2100 1450 38
5-7
■ MODE SELECTION SYSTEM (CLUSTER TYPE 2)
1. POWER MODE SELECTION SYSTEM
Main control valve
Engine
P1 P2
Pump shift
EPPR
Drive signal
Power mode
pilot lamp
MCU
Power mode switch signal Accel dial signal CN-16A CN-16
Work mode switch signal Normal
User mode switch signal
CN-16B
Emergency
Accel dial
Cluster
3009SH5MS21
Mode selection system (micro computer based electro-hydraulic pump and engine mutual control
system) optimizes the engine and pump performance.
The combination of 2 power modes (H, S) and accel dial position (10 set) makes it possible to use
the engine and pump power more effectively corresponding to the work conditions from a heavy and
great power requesting work to a light and precise work.
Engine rpm Power shift by EPPR valve
Power Standard Option Standard Option
Application
mode
Current Pressure Current Pressure
Unload Load Unload Load
(mA) (kgf/cm2) (mA) (kgf/cm2)
M Maximum power 2100±50 1900±50 2100±50 1900±50 330±30 10±3 280±30 7
H High power 2000±50 1800±50 2050±50 1850±50 330±30 10±3 280±30 7
S Standard power 1900±50 1700±50 1950±50 1750±50 330±30 10±3 330±30 10±3
AUTO Engine
1150±100 - 1150±100 - 700±30 38±3 700±30 38±3
DECEL deceleration
One touch Engine quick
1000±100 - 1000±100 - 700±30 38±3 700±30 38±3
decel deceleration
KEY Key switch
1000±100 - 1000±100 - 700±30 38±3 700±30 38±3
START start position
5-8
2. WORK MODE SELECTION SYSTEM
2 Work modes can be selected for the optional work speed of the machine operation.
Main control valve
Arm 1 Arm 2
Option Bucket
Boom 2 Boom 1
Swing Travel(LH)
Travel(RH)
Engine
Pump shift
EPPR
Drive signal
Power mode
pilot lamp MCU Accel dial signal CN-16A CN-16
Work mode switch signal
Normal
CN-16B
Emergency
Accel dial
Cluster
3309S5MS22
1) HEAVY DUTY WORK MODE

Boom and arm operation speed faster than general work mode.
2) GENERAL WORK MODE
When key switch is turned ON, this mode is selected and swing operation speed is faster than
heavy duty work mode.
Work mode Heavy duty work solenoid Max flow cut-off solenoid
Heavy duty OFF OFF
General ON OFF
5-9
3. USER MODE SELECTION SYSTEM
An operator can change the engine and pump power and memorize it for his preference.
Mode Operation
High idle rpm, auto decel rpm
U
EPPR pressure can be modulated and memorized separately
HOW TO MPDULATE THE MEMORY SET

1) Each memory mode has a initial set which are
mid-range of max engine speed, auto decel
rpm, and EPPR valve input current. ACCEL
DECEL
2) High idle rpm, auto decel rpm, EPPR pressure
EPPR
can be modulated and memorized separately in
the U-mode. 2507A4OP08
※ Refer to the page 5-68 for set of use mode.

·LCD
LCD segment vs parameter setting
SYSTEM MENU
Segment ACCEL DECEL EPPR
( ) (rpm) (rpm) (mA)
Monitoring Diagnosis Management
1 1500 1000 (low idle) 150

2 1600 1050 200 Settings Display User Mode
3 1700 1100 250 User mode icon

4 1800 1150 (decel rpm) 300
5 1850 1200 350
ACCEL
6 1900 1250 400 DECEL
7 1950 1300 450 EPPR
8 2000 1350 500

9 2050 1400 550
10 2100 1450 600
3009SH4OP05
5-10
GROUP 3 AUTOMATIC DECELERATION SYSTEM (CLUSTER TYPE 1)
Work Travel
pressure pressure
Main control valve

Engine
Cluster
Pressure signal

MCU
Normal
Auto idle
pilot lamp CN-16B
Emergency
Accel dial
Auto idle switch signal
3009SH5MS05
1. WHEN AUTO IDLE PILOT LAMP ON

When all of the work equipment control levers including swing and travel levers are at neutral for 4
seconds, MCU drives the accel actuator to reduce the engine speed to 1150 rpm. If the control levers
are at neutral for 1 minute, MCU reduces the engine speed to 1000 rpm. As the result of reducing the
engine speed, fuel consumption and noise are effectively cut down during non-operation of the
control levers.
When the Auto idle pilot lamp is turned off by pressing the switch or any control lever is operated, the
reduced engine speed rises upto the speed before deceleration in a second.
Engine rpm
Accel dial
set rpm
Auto idle 1150 rpm

rpm
4 sec
Low idle 1000 rpm
rpm
60 sec 1sec
Lever Lever Time

neutral operation
3009SH5MS06
2. WHEN AUTO IDLE PILOT LAMP OFF

The engine speed can be set as desired using the accel dial switch, and even if the control levers are
neutral, the engine speed is not reduced.
※ Auto idle function can be activated when accel dial position is over 4.
5-11
■ AUTOMATIC DECELERATION SYSTEM (CLUSTER TYPE 2)
Work Travel
pressure pressure
Main control valve

Engine
P3
Pump power
shift EPPR
Signal
Pressure signal
MCU Accel dial signal CN-16A CN-16
Normal
CN-16B
Emergency
Auto decel
pilot lamp
Accel dial
Cluster
3009SH5MS23
1. WHEN AUTO IDLE PILOT LAMP ON

When all of the work equipment control levers including swing and travel levers are at neutral for 4
seconds, MCU drives the accel actuator to reduce the engine speed to 1150 rpm. If the control levers
are at neutral for 1 minute, MCU reduces the engine speed to 1000 rpm. As the result of reducing the
engine speed, fuel consumption and noise are effectively cut down during non-operation of the
control levers.
When the Auto idle pilot lamp is turned off by pressing the switch or any control lever is operated, the
reduced engine speed rises upto the speed before deceleration in a second.
Engine rpm
Accel dial
set rpm
Auto idle 1150 rpm

rpm
4 sec
Low idle 1000 rpm
rpm
60 sec 1sec
Lever Lever Time

neutral operation
3009SH5MS06
2. WHEN AUTO IDLE PILOT LAMP OFF

The engine speed can be set as desired using the accel dial switch, and even if the control levers are
neutral, the engine speed is not reduced.
※ Auto idle function can be activated when accel dial position is over 4.
5-12
GROUP 4 POWER BOOST SYSTEM (CLUSTER TYPE 1)
Main control valve
Arm 1 Arm 2
Option Bucket
Boom 2 Boom 1
Swing Travel(LH)
Travel(RH)
Main relief
valve
P1 P2
pressure pressure
Power boost
solenoid valve
Engine

Pump power
Power boost shift EPPR
button
Signal
LH control
lever Drive signal
Power boost button signal
Pressure signal
MCU
Normal
CN-16B
Emergency
Accel dial
Power mode sw signal
Power max
pilot lamp
Cluster
3309S5MS07
· When the power boost switch on the left control lever knob is pushed ON, the power mode is set P
mode and maximum digging power is increased by 10 %.
· When the power boost function is activated, the power boost solenoid valve pilot pressure raises the
set pressure of the main relief valve to increase the digging power.
Description Condition Function
- Power mode : P
- Accel dial power : 9
Power boost switch : ON
Activated - Power boost solenoid : ON
Accel dial : over 8
- Power boost pilot lamp : ON
- Operating time : max 8 seconds
- Pre-set power mode
Canceled Power boost switch : OFF - Power boost solenoid : OFF
- Power boost pilot lamp : OFF
※ When the auto power boost is set to Enable and power mode is set to P mode on the cluster, the
digging power is automatically increased as working conditions by the MCU. It is operated max 8
seconds.
5-13
■ POWER BOOST SYSTEM (CLUSTER TYPE 2)
Main control valve
Arm 1 Arm 2
Option Bucket
Boom 2 Boom 1
Swing Travel(LH)
Travel(RH)
Main relief
valve
P1 P2
pressure pressure
Power boost
solenoid valve
Engine
Main pump
P1 P2
P3
Pilot pump
Pump power
shift EPPR
Power boost
button
Signal
Pressure signal
LH control
lever Drive signal
MCU
Power max button signal Accel dial signal CN-16A CN-16
Power mode switch signal Normal
CN-16B
Emergency
Cluster Accel dial
3309S5MS24
· When the power boost switch on the left control lever knob is pushed ON, the maximum digging
power is increased by 10 %.
· When the power set is at M, H or S and the power boost function is activated, the power solenoid
valve pilot pressure raises the set pressure of the main relief valve to increase the digging power.
Power boost switch

Description
OFF ON
H or S H
Power set
M M
Main relief valve set pressure 350 kgf/cm2 380 kgf/cm2
Even when pressed continuousty, it
Time of operation -
is canceled after 8 sec.
※ Default - Power boost solenoid valve : OFF
5-14
GROUP 5 TRAVEL SPEED CONTROL SYSTEM (CLUSTER TYPE 1)
Main control valve Travel motor
Arm 1 Arm 2
Option Bucket
Regulator
Boom 2 Boom 1
Swing Travel(LH)
Travel(RH) Travel speed

solenoid valve
Engine

Cluster
Drive signal
MCU
Travel speed
pilot lamp
Travel speed switch signal
3309S5MS06
Travel speed can be switched manually by pressing the travel speed switch on the cluster.
Travel speed Lamp

Speed Operation
solenoid valve on cluster
Low OFF Turtle Low speed, high driving torque in the travel motor
High ON Rabbit High speed, low driving torque in the travel motor
※ Default : Turtle (Low)
5-15
■ TRAVEL SPEED CONTROL SYSTEM (CLUSTER TYPE 2)
Main control valve Travel motor
Arm 1 Arm 2
Option Bucket
Regulator
Boom 2 Boom 1
Swing Travel(LH)
Travel(RH) Travel speed

solenoid valve
Engine
Drive signal
Travel speed pilot lamp MCU
Travel speed switch signal
Cluster
3309S5MS25
Travel speed can be switched manually by pressing the travel speed switch on the cluster.
Travel speed Lamp
Speed Operation
solenoid valve on cluster
Low OFF Turtle Low speed, high driving torque in the travel motor
High ON Rabbit High speed, low driving torque in the travel motor
※ Default : Turtle (Low)
5-16
GROUP 6 AUTOMATIC WARMING UP SYSTEM (CLUSTER TYPE 1)
Main control valve

Engine
Coolant
temp sensor

Pump power
shift EPPR
Coolant temperature signal

Hydraulic temp signal
Cluster MCU Drive signal Hydraulic temp sensor
Normal
CN-16B
Emergency
Accel dial
Warming up pilot lamp signal
Warming up pilot lamp
3009SH5MS08
1. The MCU reads engine coolant temperature through the temperature sensor, and if the coolant
temperature is below 30˚C, it increases the engine speed from key start rpm to 1150rpm. At this
time the mode does not change. If the coolant temperature sensor has fault, the hydraulic oil
temperature signal is substituted.
2. In case of the coolant temperature increases up to 30˚C, the engine speed is decreased to key start
speed. And if an operator changes power mode set during the warming up function, the MCU
cancels the automatic warming up function.
3. LOGIC TABLE

- Coolant temperature : - Power mode : Default (E mode)
Actuated below 30˚C (after engine run) - Warming up time : 10 minutes (max)
- Warming up pilot lamp : ON
- Coolant temperature : Above 30˚C - Power mode : set mode

- Warming up time : Above 10 minutes - Warming up pilot lamp : OFF
- Changed power mode set by operator
Canceled - RCV lever or pedal operating
- Auto idle cancel
※ If any of the above conditions is
applicable, the automatic warming up
function is canceled
5-17
■ AUTOMATIC WARMING UP SYSTEM (CLUSTER TYPE 2)
Main control valve

Engine

Cluster Pump power
shift EPPR
Coolant temp signal

Warming up
pilot lamp MCU Coolant temp sensor
Drive signal
Warming up pilot lamp signal
Normal
CN-16B
Emergency
Accel dial
3009SH5MS26
1. The MCU reads engine coolant temperature through the temperature sensor, and if the coolant
temperature is below 30˚C, it increases the engine speed from key start rpm to 1150rpm. At this
time the mode does not change.
2. In case of the coolant temperature increases up to 30˚C, the engine speed is decreased to key start
speed. And if an operator changes mode set during the warming up function, the MCU cancels the
automatic warming up function.
3. LOGIC TABLE
- Coolant temperature : - Power mode : Default (S mode)
Actuated below 30˚C (after engine run) - Warming up time : 10 minutes (max)
- Accel dial poisition is under 30˚C - Warming up lamp : ON
- Coolant temperature : Above 30˚C - Power mode : set mode

- Warming up time : Above 10 minutes - Warming up pilot lamp : OFF
- Changed mode set by operator
Canceled - Increase engine speed by rotating accel
dial clockwise
※ If any of the above conditions is
applicable, the automatic warming up
function is canceled
Warming up lamp - Coolant temperature : Above 30˚C - Warming up lamp : OFF
5-18
GROUP 7 ENGINE OVERHEAT PREVENTION SYSTEM (CLUSTER TYPE 1)
Main control valve

Engine
Coolant
temp sensor

Pump power
shift EPPR

Emergency
warning lamp MCU Drive signal
Hydraulic temp sensor
Cluster
Normal
CN-16B
Emergency
Accel dial
Overheat warning signal
Coolant temperature Hydraulic temperature

warning lamp warning lamp
3009SH5MS09A
1. The engine coolant temperature or the hydraulic oil temperature is overheated over 100˚C, the
warning lamp is ON and the pump input torque or the engine speed is reduced as below logic table.
2. LOGIC TABLE
- Coolant or hydraulic oil temperature : - Warning lamp & buzzer : ON
Activated
First step Above 100˚C - Pump input torque is reduced.
warning - Coolant or hydraulic oil temperature : - Return to pre-set the pump input torque.
Canceled
Less than 95˚C
- Emergency warning lamp pops up on the
- Coolant or hydraulic oil temperature :
Activated center of LCD and the buzzer sounds.
Above 105˚C
Second step - Engine speed is reduced after 10 seconds.
warning - Return to pre-set the engine speed.
- Coolant or hydraulic oil temperature :
Canceled - Hold pump input torque on the first step
Less than 100˚C
warning.
5-19
■ ENGINE OVERHEAT PREVENTION SYSTEM (CLUSTER TYPE 2)
Main control valve

Engine
Coolant
temp sensor

Pump power
shift EPPR

Hydraulic temperature Coolant temperature MCU Drive signal Hydraulic temp sensor
warning lamp warning lamp
Normal
CN-16B
Emergency
Accel dial
Overheat warning signal
Cluster 3009SH5MS27
1. MCU receives engine coolant temperature through the temperature sensor and when the engine
coolant boils up to 110˚C, it sends overheat warning signal to the cluster and decrease the engine
speed same as accel dial 7 position.
2. If the coolant temperature drops less than 100˚C, the MCU returns the mode to the mode set before.
And if mode set is changed during the function, the MCU cancels the function.
Even if the overheat prevention function is canceled by mode change, the overheat warning lamp
turns OFF only when the coolant temperature is less than 100˚C.
3. LOGIC TABLE
- Coolant temperature : Above 110˚C - Engine rpm drop to accel dial 7 position
Actuated
- Accel dial set : Above 8 - Overheat warning lamp & buzzer : ON
- Coolant temperature : Less than 100˚C - Return to the mode and accel dial set before
- Changed mode set by operator - Hold on the changed set
Canceled ※ If any of the above conditions is
applicable, engine overheat
prevention function is canceled
Overheat warning lamp - Coolant temperature : Less than 100˚C - Overheat warning lamp : OFF
5-20
GROUP 8 VARIABLE POWER CONTROL SYSTEM (CLUSTER TYPE 1)
Work Travel
pressure pressure
Main control valve
P1 P2
pressure pressure
Engine

Pump power
shift EPPR
Signal
Pressure signal
MCU Pressure signal

Switch signal
Pressure signal Accel dial signal CN-16A CN-16
LH control RH control
lever lever Normal
CN-16B
Emergency
AO AI BI BU
Accel dial
Shuttle
block
Boom up
pressure
E mode power
Cluster
3009SH5MS10
· The variable power control system controls the engine and pump mutual power according to RCV
lever stroke and pump load.
It makes fuel saving and smooth control at precise work.
Description Working condition
Power mode E
Work mode General (bucket)
Pressure sensor Normal
※ The variable power control function can be activated when the power mode is set to E mode.
5-21
GROUP 9 ATTACHMENT FLOW CONTROL SYSTEM (CLUSTER TYPE 1)
Attachment pilot
pressure sensor
Main control valve
Work tool
Arm 1 Arm 2
SOLENOID VALVE
Option Bucket
Attachment
pressure
Boom 2 Boom 1
Attachment
conflux
Swing Travel(LH)
Attachment
Travel(RH) safety
Engine

Attachment
flow EPPR
Cluster
Drive signal
Drive signal
MCU
Pressure signal
Normal
CN-16B
Emergency
Work mode Work mode switch signal
pilot lamp
Accel dial
3309S5MS11
· The system is used to control the pump delivery flow according to set of the work tool on the
cluster by the attachment flow EPPR valve.
Work tool
Description
Breaker Crusher
Max 7 step, Max 4 step,
Flow level reduced 10 lpm each step reduced 20 lpm each step
Attach safety solenoid ON ON
Attach pressure solenoid OFF ON
Attach conflux solenoid OFF ON/OFF
※ Refer to the page 5-51 for the attachment kinds and max flow.
5-22
GROUP 10 ANTI-RESTART SYSTEM
Engine
Starter
Start safety relay
Drive signal
MCU
Normal
CN-16B
Emergency
Accel dial
3009SH5MS12
1. ANTI-RESTART FUNCTION
After a few seconds from the engine starts to run, MCU turns off the start safety relay to protect the
starter from inadvertent restarting.
2. When a replacement or taking-off of the MCU is needed, connect CN-16 and CN-16B to ensure the
engine start without the MCU.
5-23
GROUP 11 SELF-DIAGNOSTIC SYSTEM (CLUSTER TYPE 1)
1. OUTLINE
When any abnormality occurs in the ADVENCED CAPO system caused by electric parts
malfunction and by open or short circuit, the MCU diagnoses the problem and sends the error codes
to the cluster and also stores them in the memory.
2. MONITORING
1) Active fault
21093CD66
21093CD66A-1 21093CD66B
· The active faults of the MCU can be checked by this menu.
2) Logged fault
21093CD66C
21093CD66D-1 21093CD66E
· The logged faults of the MCU can be checked by this menu.
3) Delete fault
21093CD66F
21093CD66G 21093CD66H
· The logged faults of the MCU can be deleted by this menu.
5-24
3. MACHINE ERROR CODES TABLE
Error code
Description
HCESPN FMI
3 Hydraulic oil temperature sensor circuit - Voltage above normal, or shorted to high source.
101
4 Hydraulic oil temperature circuit - Voltage below normal, or shorted to low source.
0 Working pressure sensor data above normal range.
1 Working pressure sensor data below normal range.
105
2 Working pressure sensor data error.
4 Working pressure sensor circuit - Voltage below normal, or shorted to Low source.
0 Travel oil pressure sensor data above normal range.
1 Travel oil pressure sensor data below normal range.
108
2 Travel oil pressure sensor data error.
4 Travel oil pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Main pump 1 (P1) pressure sensor data above normal range.
1 Main pump 1 (P1) pressure sensor data below normal range.
120 2 Main pump 1 (P1) pressure sensor data error.
Main pump 1 (P1) pressure sensor circuit - Voltage below normal, or shorted to low
4
source.
0 Main pump 2 (P2) pressure sensor data above normal range.
1 Main pump 2 (P2) pressure sensor data below normal range.
121 2 Main pump 2 (P2) pressure sensor data error.
Main pump 2 (P2) pressure sensor circuit - Voltage below normal, or shorted to low
4
source.
0 Overhead pressure sensor data above normal range.
1 Overhead pressure sensor data below normal range.
122
2 Overhead pressure sensor data error.
4 Overhead pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Negative 1 pressure sensor data above normal range.
1 Negative 1 pressure sensor data below normal range.
123
2 Negative 1 pressure sensor data error.
4 Negative 1 pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Negative 2 Pressure sensor data above normal range.
1 Negative 2 Pressure sensor data below normal range.
124
2 Negative 2 Pressure sensor data error.
4 Negative 2 Pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Pilot pump (P3) pressure sensor data above normal range.
1 Pilot pump (P3) pressure sensor data below normal range.
125
2 Pilot pump (P3) pressure sensor data error.
4 Pilot pump (P3) pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Boom up pilot pressure sensor data above normal range.
1 Boom up pilot pressure sensor data below normal range.
127
2 Boom up pilot pressure sensor data error.
4 Boom up pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Swing pilot pressure sensor data above normal range.
1 Swing pilot pressure sensor data below normal range.
135
2 Swing pilot pressure sensor data error.
4 Swing pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
※ Some error codes are not applied to this model.
5-25
Error code
Description
HCESPN FMI
0 Attachment pilot pressure sensor data above normal range.
1 Attachment pilot pressure sensor data below normal range.
138
2 Attachment pilot pressure sensor data error.
4 Attachment pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
5 Pump EPPR valve circuit - Current below normal, or open circuit.
140
6 Pump EPPR valve circuit - Current above normal.
5 Boom priority EPPR valve circuit - Current below normal, or open circuit.
141
6 Boom priority EPPR valve circuit - Current above normal.
5 Travel EPPR valve circuit - Current below normal, or open circuit.
143
6 Travel EPPR valve circuit - Current above normal.
5 Attachment flow EPPR valve circuit - Current below normal, or open circuit.
144
6 Attachment flow EPPR valve circuit - Current above normal.
5 Remote cooling fan EPPR valve circuit - Current below normal, or open circuit.
145
6 Remote cooling fan EPPR valve circuit - Current above normal.
5 Left rotate EPPR valve circuit - Current below normal, or open circuit.
150
6 Left rotate EPPR valve circuit - Current above normal.
5 Right rotate EPPR valve circuit - Current below normal, or open circuit.
151
6 Right rotate EPPR valve circuit - Current above normal.
5 Left tilt EPPR valve circuit - Current below normal, or open circuit.
152
6 Left tilt EPPR valve circuit - Current above normal.
5 Right tilt EPPR valve circuit - Current below normal, or open circuit.
153
6 Right tilt EPPR valve circuit - Current above normal.
5 Power max solenoid circuit - Current below normal, or open circuit.
166
6 Power max solenoid circuit - Current above normal.
5 Travel speed solenoid circuit - Current below normal, or open circuit.
167
6 Travel speed solenoid circuit - Current above normal.
5 Attachment pressure solenoid circuit - Current below normal, or open circuit.
168
6 Attachment pressure solenoid circuit - Current above normal.
5 Attachment conflux solenoid circuit - Current below normal, or open circuit.
169
6 Attachment conflux solenoid circuit - Current above normal.
5 Arm regeneration solenoid circuit - Current below normal, or open circuit.
170
6 Arm regeneration solenoid circuit - Current above normal.
5 Attachment safety solenoid circuit - Current below normal, or open circuit.
171
6 Attachment safety solenoid circuit - Current above normal.
5 Remote cooling fan reverse solenoid circuit - Current below normal, or open circuit.
181
6 Remote cooling fan reverse solenoid circuit - Current above normal.
0 Pump EPPR 2nd pressure sensor data above normal range.
1 Pump EPPR 2nd pressure sensor data below normal range.
200
2 Pump EPPR 2nd pressure sensor data error.
4 Pump EPPR 2nd pressure sensor circuit - Voltage below normal, or shorted to low source.
5 Fuel level sensor circuit - Voltage above normal, or shorted to high source.
301
6 Fuel level sensor circuit - Voltage below normal, or shorted to low source.
Engine coolant temperature sensor circuit - Voltage above normal, or shorted to high
3
source.
304
Engine coolant temperature sensor circuit - Voltage below normal, or shorted to low
4
source.
310 8 Engine speed signal error - Abnormal frequency or pulse width.
3 Engine preheat relay circuit - Voltage above normal, or shorted to high source.
322
4 Engine preheat relay circuit - Voltage below normal, or shorted to low source.
3 Fuel warmer relay circuit - Voltage above normal, or shorted to high source.
325
4 Fuel warmer relay circuit - Voltage below normal, or shorted to low source.
5-26
Error code
Description
HCESPN FMI
3 Potentiometer (G/A) circuit - Voltage above normal, or shorted to high source.
340
4 Potentiometer (G/A) circuit - Voltage below normal, or shorted to low source.
5 Governor actuator circuit - Current below normal, or open circuit.
341
6 Governor actuator circuit - Current above normal.
0 Transmission oil pressure sensor data above normal range.
1 Transmission oil pressure sensor data below normal range.
501
2 Transmission oil pressure sensor data error.
4 Transmission oil pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Brake pressure sensor data above normal range.
1 Brake pressure sensor data below normal range.
503
2 Brake pressure sensor data error.
4 Brake pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Working brake pressure sensor data above normal range.
1 Working brake pressure sensor data below normal range.
505
2 Working brake pressure sensor data error.
4 Working brake pressure sensor circuit - Voltage below normal, or shorted to low source.
3 Working brake lamp circuit - Voltage above normal, or shorted to high source.
506
4 Working brake lamp circuit - Voltage below normal, or shorted to low source.
3 Ram lock lamp circuit - Voltage above normal, or shorted to high source.
520
4 Ram lock lamp circuit - Voltage below normal, or shorted to low source.
5 Ram lock solenoid circuit - Current below normal, or open circuit.
525
6 Ram lock solenoid circuit - Current above normal.
0 Travel F pilot pressure sensor data above normal range.
1 Travel F pilot pressure sensor data below normal range.
530
2 Travel F pilot pressure sensor data error.
4 Travel F pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Travel R pilot pressure sensor data above normal range.
1 Travel R pilot pressure sensor data below normal range.
531
2 Travel R pilot pressure sensor data error.
4 Travel R pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
3 Hourmeter circuit - Voltage above normal, or shorted to high source.
701
4 Hourmeter circuit - Voltage below normal, or shorted to low source.
0 MCU input voltage high.
705
1 MCU input voltage low.
707 1 Alternator node I voltage low.
3 Acc. dial circuit - Voltage above normal, or shorted to high source.
714
4 Acc. dial circuit - Voltage below normal, or shorted to low source.
3 Rotate signal input circuit - Voltage above normal, or shorted to high source.
715
4 Rotate signal input circuit - Voltage below normal, or shorted to low source.
3 Tilt signal input circuit - Voltage above normal, or shorted to high source.
716
4 Tilt signal input circuit - Voltage below normal, or shorted to low source.
3 Travel alarm (buzzer) circuit - Voltage above normal, or shorted to high source.
722
4 Travel alarm (buzzer) circuit - Voltage below normal, or shorted to low source.
830 12 MCU internal memory error.
840 2 Cluster communication data error.
843 2 Option #1 (CAN 2) communication data error.
850 2 RCM communication data error.
5-27
■ SELF-DIAGNOSTIC SYSTEM (CLUSTER TYPE 2)
1. OUTLINE
When any abnormality occurs in the NEW CAPO system caused by electric parts malfunction and
by open or short circuit, the MCU diagnoses the problem and sends the error codes to the cluster
and also stores them in the memory.
2. CURRENT
URRENT ERROR DISPLAY
(Error display)
(Recorded error delete)
5-28
3. ERROR CODES TABLE
Error code No. Description
1 Short circuit in accel actuator system
2 Potentiometer circuit is shorted to Vcc (5V) or battery +
3 Short circuit in pump EPPR valve system
4 Short circuit in boom down EPPR valve system
5 Short circuit in travel speed solenoid system
6 Short circuit in power boost solenoid system
7 Short circuit in max flow solenoid system
10 Short circuit in hour-meter system
11 Accel dial circuit is shorted to Vcc (5 V) or battery +
12 P1 pressure sensor circuit is shorted to power supply (24V) line
15 Boom down pressure circuit is shorted to power supply (24V) line
16 Accel actuator circuit is open or shorted to ground
17 Potentiometer circuit is open or shorted to ground
18 Pump EPPR valve circuit is open or shorted to ground
19 Boom down EPPR valve circuit is open or shorted to ground
20 Travel speed solenoid circuit is open or shorted to ground
21 Power boost solenoid circuit is open or shorted to ground
22 Max flow solenoid circuit is open or shorted to ground
25 Hour-meter circuit is open or shorted to ground
26 Accel dial circuit is open or shorted to ground
27 P1 pressure sensor circuit is open or shorted to ground
30 Boom down pressure sensor circuit is open or shorted to ground
31 Engine preheater circuit is open or shorted to ground
32 Travel alarm buzzer circuit is open or shorted to ground
33 Altemator circuit is open or shorted to ground
34 Controller input voltage is below 18V
5-29
Error code No. Description
35 Controller input voltage is below 38V
36 Communication error with cluster
37 Engine speed sensor circuit is open or shorted to ground
38 Aati-restart relay circuit is open or shorted to ground
39 Accel actuator does not stop at a target position
40 There is more than 500 rpm difference between target speed and actual speed
41 Hydraulic oil temperature sensor circuit is shorted to ground
42 Fuel level sensor circuit is shorted to ground
43 Coolant temperature sensor circuit is shorted to ground
44 Boom up pressure sensor circuit is shorted to power supply (24V) line
45 Hydraulic oil temperature sensor circuit is open or shorted to battery +
46 Fuel level sensor circuit is open or shorted to battery +
47 Coolant temperature sensor circuit is open or shorted to battery +
48 Boom up pressure sensor circuit is open or shorted to ground
49 Engine preheater circuit is shorted to battery +
51 Heavy duty work solenoid circuit is open or shorted to battery +
56 Travel alarm buzzer circuit is shorted to battery +
58 Heavy duty work solenoid circuit is shorted to battery +
5-30
GROUP 12 ENGINE CONTROL SYSTEM
1. MCU (Machine Control Unit)
HY
UN
MO DA
DE I
L:
R3
20
-9
FUEL TANK
TOOL BOX
Fuel tank
LED
HY
1 MCU
UN
MO DA
DE I
L:
R2
10
-9
CN
2 Bolt (M8)
-51
1
2 CN
-52
3009SH5MS13
2. MCU ASSEMBLY
1) To match the pump absorption torque with the engine torque, MCU varies EPPR valve output
pressure, which control pump discharge amount whenever feedbacked engine speed drops under
the reference rpm of each mode set.
2) Three LED lamps on the MCU display as below.
LED lamp Trouble Service
G is turned ON Normal -
G and R are turned ON Trouble on MCU - Change the MCU
Trouble on serial - Check if serial communication lines between controller
G and Y are turned ON
communication line and cluster are disconnected
Three LED are turned - Check if the input power wire (24 V, GND) of controller
Trouble on MCU power
OFF is disconnected Check the fuse
G : green, R : red, Y : yellow
5-31
3. EXCHANGE METHOD OF THE ROM IN
2
THE CLUSTER (TYPE 2)
1) Disassemble screws (2) and wiper motor 4
cover (1).
3
2) Disassemble hexgon socket bolts (3) and 1
cluster (4).
3009SH5MS28
4) Loosen the screws (6EA) located back of

the cluster. Screw
5) Then you can open the upper case of the

Cluster
cluster easily.
Upper case
3009SH5MS29
6) Install the new ROM. (Be careful of

direction and assemlbe the cluster in the
reverse order to removal).
Same
direction
21075MS14
5-32
GROUP 13 EPPR VALVE (CLUSTER TYPE 1)
1. PUMP EPPR VALVE

1) COMPOSITION
EPPR (Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve
installed at main pump.
(1) Electro magnet valve
Receive electric current from MCU and move the spool proportionally according to the specific
amount of electric current value.
(2) Spool valve
Is the two way direction control valve for pilot pressure to reduce main pump flow.
When the electro magnet valve is activated, pilot pressure enters into flow regulator of main pump.
(3) Pressure and electric current value for each mode
Pressure Electric current Engine rpm
Mode
kgf/cm
2 psi (mA) (at accel dial 10)
P 12 ± 3 171 ± 40 360 ± 30 2100 ± 50
Standard
S 12 ± 3 171 ± 40 360 ± 30 2000 ± 50
(Stage : 1.0)
E 12 ± 3 171 ± 40 360 ± 30 1900 ± 50
P 7±3 100 ± 40 280 ± 30 2100 ± 50
Option
S 7±3 100 ± 40 280 ± 30 2050 ± 50
(Stage : 2.0)
E 12 ± 3 171 ± 40 360 ± 30 1950 ± 50
2) HOW TO SWITCH THE STAGE (1.0 ↔ 2.0) ON THE CLUSTER

You can switch the EPPR valve pressure set by selecting the stage (1.0 ↔ 2.0).
- Management
·Service menu
21093CD67M
21093CD67N 21093CD67P
Enter the password
21093CD67ZZ
· Power shift (standard/option) : Power shift pressure can be set by option menu.
5-33
■ EPPR VALVE (CLUSTER TYPE 2)
1. PUMP EPPR VALVE

1) COMPOSITION
EPPR (Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve
installed at main pump.
(1) Electro magnet valve
Receive electric current from MCU and move the spool proportionally according to the specific
amount of electric current value.
(2) Spool valve
Is the two way direction control valve for pilot pressure to reduce hydraulic pump flow.
When the electro magnet valve is activated, pilot pressure enters into flow regulator of hydraulic
pump.
So, pump flow decreases to prevent engine stall.
(3) Pressure and electric current value for each mode
Pressure Electric current Engine rpm
Mode
kgf/cm
2 psi (mA) (at accel dial 10)
M 10 ± 3 142 ± 40 330 ± 30 2100 ± 50
Standard
H 10 ± 3 142 ± 40 330 ± 30 2000 ± 50
(Stage : 1.0)
S 10 ± 3 142 ± 40 330 ± 30 1900 ± 50
M 7±3 100 ± 40 280 ± 30 2100 ± 50
Option
H 7±3 100 ± 40 280 ± 30 2050 ± 50
(Stage : 2.0)
S 10 ± 3 142 ± 40 330 ± 30 1950 ± 50
2) HOW TO SWITCH VERSION (3.1 ↔ 4.1) ON THE CLUSTER

You can switch the EPPR valve pressure set by selecting the version (3.1 ↔ 4.1).
- Dual mode
·Changing the MCU mode
5-34
3) OPERATING PRINCIPLE (pump EPPR valve, cluster type 1,2)
(1) Structure
6 7
2 3 4 5
5-22(1)
1 Sleeve 4 O-ring 6 Solenoid valve

2 Spring 5 O-ring 7 Connector
3 Spool
A
P Pilot oil supply line (pilot pressure)
P
T Return to tank
T
A Secondary pressure to flow regulator at main pump
(2) Neutral
eutral
Pressure line is blocked and A oil returns
to tank.
P A
P T
T
A
(3) Operating
perating
Secondary pressure enters into A.
P A
T
P T
A
5-22(2)
5-35
4) EPPR VALVE CHECK PROCEDURE Spec : 100~700 mA
(Cluster type 1,2)
Adapter(P/no.:21Q6-50410)
(1) Check electric current value at EPPR valve
CN-75
① Disconnect connector CN-75 from Multimeter
EPPR valve.
② Insert the adapter to CN-75 and install
multimeter as figure. EPPR valve
③ Start engine.
④ Set power-mode and cancel auto decel
mode.
Main pump
: cluster type 1 : S mode
cluster type 2 : H mode
⑤ Position the accel dial at 10.
21095MS21
⑥ If tachometer show approx 2000±50
rpm disconnect one wire harness from
EPPR valve.
⑦ Check electric current at bucket circuit
relief position.
(2) Check pressure at EPPR valve Spec : 4~20 kgf/cm2 (60~280 psi)
① Remove plug and connect pressure
gauge as figure. Pressure adjusting
screw locknut
·Gauge capacity : 0 to 50 kgf/cm2 Supply line,
pilot pressure CN-75
(0 to 725 psi)
② Start engine.
③ Set power-mode and cancel auto decel
EPPR valve
mode.
: cluster type 1 : S mode
cluster type 2 : H mode
④ Position the accel dial at 10.
⑤ If tachometer show approx 2000±50
rpm check pressure at relief position of
bucket circuit by operating bucket control
29095MS10
lever.
⑥ If pressure is not correct, adjust it.
⑦ After adjust, test the machine.
5-36
2. BOOM PRIORITY EPPR VALVE (Cluster type 1,2)
1) COMPOSITION
The boom priority EPPR valve is built in a manifold and mainly consisting of valve body and coil.
This EPPR valve installed under the solenoid valve.
2) CONTROL
The boom priority EPPR valve has to be controlled by a specific electronic amplifier card, which is
supplying the coil with a current 580 mA at 30Ω and 24 V.
3) OPERATING PRINCIPLE
(1) Structure
1 5 4 6
P T
2 Control spool 3
21095MS14
P : Pilot supply line

P
A T : Return to tank
T
A : Secondary pressure to flow MCV
1 O-ring 3 Valve body 5 Connector

2 Support ring 4 Coil 6 Cover cap
(2) Operation
In de-energized mode the inlet port (P) is closed and the outlet port (A) is connected to tank port
(T).
In energized mode the solenoid armature presses onto the control spool with a force
corresponding to the amount of current. This will set a reduced pressure at port A. The setting is
proportional to the amount of current applied.
(3) Maximum pressure relief
If a pressure from outside is applied on port A the valve may directly switch to tank port (T) and
protect the system before overload.
5-37
2) EPPR VALVE CHECK PROCEDURE Spec : 400~600 mA
(combined boom up and swing operation)
(1) Check electric current value at EPPR
valve
① Disconnect connector CN-133 from Solenoid valve
EPPR valve.
② Insert the adapter to CN-133 and install Boom priority
multimeter as figure. EPPR valve
③ Start engine.
④ If rpm display approx 2000±50 rpm CN-133
disconnect one wire harness from EPPR
valve.
⑤ Check electric current in case of Adapter
Multimeter (P/no.:21Q6-50410)
combined boom up and swing operation.
21095MS15
(2) Check pressure at EPPR valve Spec : 12~37 kgf/cm2 (170~530 psi)
① Remove hose from A5 port and connect (bucket relief operation)
pressure gauge as figure.
·Gauge capacity : 0 to 50 kgf/cm2 Pressure
gauge
(0 to 725 psi)
A5
② Start engine.
③ If rpm display approx 2000±50 rpm
check pressure at relief position of Solenoid valve
bucket circuit by operating bucket control
lever. Boom priority
EPPR valve
④ If pressure is not correct, adjust it.
⑤ After adjust, test the machine.
21095MS16
5-38
GROUP 14 MONITORING SYSTEM (CLUSTER TYPE 1)
1. OUTLINE
Monitoring system consists of the monitor part and switch part.
The monitor part gives warnings when any abnormality occurs in the machine and informs the
condition of the machine.
Various select switches are built into the monitor panel, which act as the control portion of the machine
control system.
2. CLUSTER
1) MONITOR PANEL
Time display
Warning lamps
(See page 5-43)
Gauge(See page 5-42)

Main menu(See page 5-50)
Engine rpm/Tripmeter
(See page 5-42)
Pilot lamps
(See page 5-46)
Switches
(See page 5-48)
3009SH5MS31
5-39
2) CLUSTER CHECK PROCEDURE
(1) Start key : ON
① Check monitor
a. Buzzer sounding for 4 seconds with HYUNDAI logo on cluster.
※ If the ESL mode is set to the enable, enter the password to start engine.
② After initialization of cluster, the operating screen is displayed on the LCD.
Also, self diagnostic function is carried out.
a. Engine rpm display : 0 rpm
b. Engine coolant temperature gauge : White range
c. Hydraulic oil temperature gauge : White range
d. Fuel level gauge : White range
※ When engine coolant temperature below 30˚C, the warming up pilot lamp lights up.
③ Indicating lamp state
a. Power mode pilot lamp : E mode or U mode
b. Work mode pilot lamp : General operation mode (bucket)
c. Travel speed pilot lamp : Low (turtle)
(2) Start of engine

① Check machine condition
a. RPM display indicates at present rpm
b. Gauge and warning lamp : Indicate at present condition.
※ When normal condition : All warning lamp OFF
c. Work mode selection : General work
d. Power mode selection : E mode or U mode
e. Travel speed pilot lamp : Low (turtle)
② When warming up operation
a. Warming up pilot lamp : ON
b. After engine started, engine speed increases to 1200rpm.
※ Others same as above.
③ When abnormal condition
a. The warning lamp lights up and the buzzer sounds.
b. If BUZZER STOP switch is pressed, buzzer sound is canceled but the lamp warning lights up
until normal condition.
※ The pop-up warning lamp moves to the original position and blink when the select switch is
pushed. Also the buzzer stops.
5-40
3. CLUSTER CONNECTOR
No. Name Signal
1 Battery 24V 20~32V
2 Signal 3 NTSC Cluster
3 GND -
4 Serial + (TX) 0~5V
5 Power IG (24V) 20~32V
6 Signal 2 NTSC 1 4
7 Camera signal NTSC
8 Serial - (RX) 0~5V CN-56
5 8
21095MS17
5-41
2) GAUGE
(1) Operation screen
Default Option 1 Engine coolant temperature gauge
2 Hydraulic oil temperature gauge
3 3 3 Fuel level gauge
1 2
1 4 RPM / Tripmeter display
2
4 4
21093CD07A
※ Operation screen type can be set by the screen type menu of the display.
Refer to page 5-60 for details.
(2) Engine coolant temperature gauge

① This gauge indicates the temperature of coolant.
·White range : 40-105˚C (104-221˚F)
·Red range : Above 105˚C (221˚F)
② If the indicator is in the red range or lamp blinks in red,
turn OFF the engine and check the engine cooling system.
※ If the gauge indicates the red range or lamp blinks in
21093CD07G
red even though the machine is on the normal condition,
check the electric device as that can be caused by the poor
connection of electricity or sensor.
(3) Hydraulic oil temperature gauge

① This gauge indicates the temperature of hydraulic oil.
·White range : 40-105˚C(104-221˚F)
·Red range : Above 105˚C(221˚F)
② If the indicator is in the red range or lamp blinks is red,
reduce the load on the system. If the gauge stays in the red
range, stop the machine and check the cause of the problem.
21093CD07E ※ If the gauge indicates the red range or lamp blinks in
(4) Fuel level gauge

① This gauge indicates the amount of fuel in the fuel tank.
② Fill the fuel when the red range, or lamp blinks in red.
※ If the gauge indicates the red range or lamp blinks in
21093CD07F
(5) RPM / Tripmeter display

① This displays the engine rpm or the tripmeter.
※ Refer to page 5-60 for details.
21093CD02D
5-42
3) WARNING LAMPS
Battery charging warning lamp Air cleaner warning lamp

Engine oil pressure warning lamp Overload warning lamp
Emergency warning lamp
Fuel level warning lamp

Engine coolant
temperature warning lamp Hydraulic oil temperature
warning lamp
4
3009SH3CD10
※ Each warning lamp on the top of the LCD pops up on the center of LCD and the buzzer sounds
when the each warning is happened. The pop-up warning lamp moves to the original position and
blinks when the select switch is pushed. And the buzzer stops.
Refer to page 5-49 for the select switch.
(1) Engine coolant temperature

① Engine coolant temperature warning is indicated two steps.
- 100˚C over : The lamp blinks and the buzzer sounds.
- 105˚C over : The lamp pops up on the center of LCD and
the buzzer sounds.
② The pop-up lamp moves to the original position and blinks
21093CD08A
when the select switch is pushed. Also, the buzzer stops and
lamp keeps blink.
③ Check the cooling system when the lamp keeps ON.
(2) Hydraulic oil temperature

① Hydraulic oil temperature warning is indicated two steps.
- 100˚C over : The lamp blinks and the buzzer sounds.
- 105˚C over : The lamp pops up on the center of LCD and
the buzzer sounds.
② The pop-up lamp moves to the original position and blinks
when the select switch is pushed. Also, the buzzer stops and
21093CD08C
lamp keeps blink.
③ Check the hydraulic oil level and hydraulic oil cooling system.
(3) Fuel level

① This warning lamp blinks and the buzzer sounds when the level
of fuel is below 69ℓ(18.2 U.S. gal).
② Fill the fuel immediately when the lamp blinks.
21093CD08B
5-43
(4) Emergency warning lamp
① This lamp pops up and the buzzer sounds when each of the
below warnings is happened.
- Engine coolant overheating (over 105˚C)
- Hydraulic oil overheating (over 105˚C)
- Pump EPPR circuit abnormal or open
21093CD30
- Attachment flow EPPR circuit abnormal or open
- MCU input voltage abnormal
- Accel dial circuit abnormal or open
- Cluster communication data error
※ The pop-up warning lamp moves to the original position and
blinks when the select switch is pushed. Also the buzzer stops.
This is same as following warning lamps.
② When this warning lamp blinks, machine must be checked and
serviced immediately.
(5) Engine oil pressure warning lamp

① This lamp blinks when the engine oil pressure is low.
② If the lamp blinks, shut OFF the engine immediately. Check oil
level.
21093CD32
(6) Battery charging warning lamp

① This lamp blinks when the battery charging voltage is low.
② Check the battery charging circuit when this lamp blinks.
21093CD34
(7) Air cleaner warning lamp

① This lamp blinks when the filter of air cleaner is clogged.
② Check the filter and clean or replace it.
21093CD35
5-44
(8) Overload warning lamp (opt)
① When the machine is overload, the overload warning lamp
blinks during the overload switch is ON. (if equipped)
② Reduce the machine load.
21093CD36
5-45
4) PILOT LAMPS
Work tool mode pilot lamp Message display

Work mode pilot lamp Travel speed pilot lamp
Power/User mode pilot lamp 4
Auto idle pilot lamp
Power max pilot lamp Maintenance pilot lamp
Preheat pilot lamp Fuel warmer pilot lamp
Warming up pilot lamp Decel
Decel pilot
pilotlamp
lamp
21093CD09
(1) Mode pilot lamps

No Mode Pilot lamp Selected mode
Heavy duty power work mode
1 Power mode Standard power mode
Economy power mode
2 User mode User preferable power mode
General operation mode
3 Work mode Breaker operation mode
Crusher operation mode
Low speed traveling

4 Travel mode
High speed traveling
5 Auto idle mode Auto idle
4
6 Work tool mode Oil flow level of breaker or crusher mode
7 Message display "Setting is completed" display after selection
(2) Power max pilot lamp

① The lamp will be ON when pushing power max switch on the
LH RCV lever.
② The power max function is operated maximum 8 seconds.
※ Refer to the operator's manual page 3-38 for power max
function.
21093CD38
5-46
(3) Preheat pilot lamp
① Turning the start key switch ON position starts preheating in
cold weather.
② Start the engine after this lamp is OFF.
21093CD39
(4) Warming up pilot lamp

① This lamp is turned ON when the coolant temperature is below
30˚C (86˚F ).
② The automatic warming up is cancelled when the engine
coolant temperature is above 30˚C, or when 10 minutes have
passed since starting the engine.
21093CD40
(5) Decel pilot lamp

① Operating one touch decel switch on the RCV lever makes the
lamp ON.
② Also, the lamp will be ON and engine speed will be lowered
automatically to save fuel consumption when all levers and
pedals are at neutral position, and the auto idle function is
21093CD41
selected.
※ One touch decel is not available when the auto idle pilot lamp
is turned ON.
※ Refer to the operator's manual page 3-38.
(6) Fuel warmer pilot lamp

10˚C (50˚F ) or the hydraulic oil temperature 20˚C (68˚F ).
② The automatic fuel warming is cancelled when the engine
coolant temperature is above 60˚C, or the hydraulic oil temper-
ature is above 45˚C since the start switch was ON position.
21093CD43
(7) Maintenance pilot lamp

① This lamp will be ON when the consuming parts are needed to
change or replace. It means that the change or replacement
interval of the consuming parts remains below 30 hours.
② Check the message in maintenance information of main menu.
Also, this lamp lights ON for 3 minutes when the start switch is
21093CD44
ON position.
5-47
5) SWITCHES
Power/User mode Auto idle pilot lamp

pilot lamp
Work mode Travel speed pilot lamp
pilot lamp
Power mode switch Escape(previous or parent menu)

Rear camera(option)
Work mode switch Auto idle/Buzzer stop switch
User mode switch Travel speed switch
Select switch
21093CD45
※ When the switches are selected, the pilot lamps are displayed on the LCD. Refer to the page
5-46 for details.
(1) Power mode switch

① This switch is to select the machine power mode and selected
power mode pilot lamp is displayed on the pilot lamp position.
·P : Heavy duty power work.
·S : Standard power work.
·E : Economy power work.
21093CD45A
② The pilot lamp changes E → S → P → E in order.
(2) Work mode switch

① This switch is to select the machine work mode, which shifts
from general operation mode to optional attachment operation
mode.
· : General operation mode
· : Breaker operation mode (if equipped)
21093CD45C
· : Crusher operation mode (if equipped)
·Not installed : Breaker or crusher is not installed.
※ Refer to the operator's manual page 4-6 for details.
5-48
(3) User mode switch
① This switch is used to memorize the current machine operating
status in the MCU and activate the memorized user mode.
·Memory : Push more than 2 seconds.
·Action : Push within 2 seconds.
·Cancel : Push this switch once more within 2 seconds.
21093CD45D
② Refer to the page 5-51 for another set of user mode.
(4) Select switch

① This switch is used to select or change the menu and input
value.
② Knob push
·Long (over 2 sec) : Return to the operation screen
·Medium (0.5~2 sec) : Return to the previous screen
21093CD45E
·Short (below 0.5 sec) : Select menu
③ Knob rotation
This knob changes menu and input value.
·Right turning : Down direction / Increase input value
·Left turning : Up direction / Decreased input value
(5) Auto idle/ buzzer stop switch

① This switch is used to activate or cancel the auto idle function.
·Pilot lamp ON : Auto idle function is activated.
·Pilot lamp OFF : Auto idle function is cancelled.
② The buzzer sounds when the machine has a problem.
In this case, push this switch and buzzer stops, but the
21093CD45F
warning lamp blinks until the problem is cleared.
(6) Travel speed control switch

① This switch is used to select the travel speed alternatively.
· : High speed
· : Low speed
21093CD45G
(7) Escape/Camera switch

① This switch is used to return to the previous menu or parent
menu.
② In the operation screen, pushing this switch will display the
view of the camera on the machine (if equipped).
Please refer to page 5-61 for the camera.
21093CD45H
③ If the camera is not installed, this switch is used only ESC
function.
5-49
6) MAIN MENU
Press
21093CD64
21093CD64B
21093CD64A
※ Please refer to select switch, page 5-49 for selection and change of menu and input value.
(1) Structure
No Main menu Sub menu Description
Work tool Breaker, Crusher, Not installed
U mode power User mode only
Boom/Arm speed Boom speed, Arm speed
1
Auto power boost Enable, Disable
Mode Initial mode Default, U mode
21093CD64D Cluster switch (back up) Switch function
Active fault MCU
Logged fault MCU
Delete logged fault All logged fault delete, Initialization canceled
2
Monitoring (analog) Machine information
Monitoring
Monitoring Monitoring (digital) Switch status, Output status
21093CD64E Operating hours Operating hours for each mode
Maintenance information Replacement, Change interval oils and filters
Machine security ESL mode setting, Password change
Machine Information Cluster, MCU, Engine, Machine
3
A/S phone number A/S phone number, A/S phone number change
Management Service menu
Management Power shift, Hourmeter start, Replacement history,
21093CD64F Update
Display item Engine speed, Tripmeter A, Tripmeter B, Tripmeter C
Clock Clock
Brightness Manual, Auto
4 Unit Temperature, Pressure, Flow, Date format
Language Korean, English, Chinese
Display
Display
Screen type A type, B type
21093CD64G
Tripmeter 3 kinds (A, B, C)

DMB DMB select, DAB select, Channel scan, Exit
Entertainment Play MP4, codec.
5
Camera setting Basic direction, Display switching, Full screen
Utilities Message box Record for fault, attachment etc.
21093CD64H
5-50
(2) Mode setup
① Work tool
21093CD65
21093CD65A 21093CD65B
A B
· A : Select one installed optional attachment.

· B : Max flow - Set the maximum flow for the attachment.
Flow level - Reduce the operating flow from maximum flow.
Breaker - Max 7 steps, Reduced 10 lpm each step.
Crusher - Max 4 steps, Reduced 20 lpm each step.
※ The flow level is displayed with the work mode pilot lamp.
② U mode power
Power
Step Engine Idle speed
speed (rpm) shift
( ) (rpm) (bar)
1 1500 1000 (low idle) 0
2 1600 1050 3
21093CD65D 3 1700 1100 6
4 1800 1150 (decel rpm) 9
21093CD65E
5 1850 1200 12
· Engine high idle rpm, auto idle rpm and pump torque 6 1900 1250 16
(power shift) can be modulated and memorized 7 1950 1300 20
separately in U-mode. 8 2000 1350 26
· U-mode can be activated by user mode switch. 9 2050 1400 32
10 2100 1450 38
③ Boom/Arm speed
21093CD65F
21093CD65G
· Boom speed
- Control type
Manual - Boom up speed is fixed as set steps.
Auto - Boom up speed is automatically adjusted as working conditions by the MCU.
- Speed setting - Boom up speed is increased as much as activated steps.
· Arm speed
- Regeneration - Arm regeneration function can be activated or cancelled.
Enable - Arm in speed is up.
Disable - Fine operation.
5-51
④ Auto power boost
21093CD65L
21093CD65M
· The power boost function can be activated or cancelled.

· Enable - The digging power is automatically increased as working conditions by the MCU.
It is operated max 8 seconds.
· Disable - Not operated.
⑤ Initial mode
21093CD65P
21093CD65Q
· Default - The initial power mode is set E mode when the engine is started.
· U mode - The initial power mode is set U mode when the engine is started.
⑥ Cluster switch (back up)
21093CD65S
21093CD65T
- The cluster switch can be selected and changed by this menu when the switches are
abnormal on the cluster.
- In order to exit "Cluster switch" mode, please put the cursor on the ESC/CAM switch by
turning the select switch and push the select switch.
- In "Cluster switch", other switches except "Select switch" do not work.
5-52
(3) Monitoring
① Active fault
21093CD66
21093CD66A-1 21093CD66B
· The active faults of the MCU can be checked by this menu.
② Logged fault
21093CD66C
21093CD66D-1 21093CD66E
· The logged faults of the MCU can be checked by this menu.
③ Delete logged fault
21093CD66F
21093CD66G 21093CD66H
· The logged faults of the MCU can be deleted by this menu.
④ Monitoring
Monitoring(Analog)
21093CD66J
21093CD66K 21093CD66L
· The machine status such as the engine rpm, oil temperature, voltage and pressure etc. can
be checked by this menu.
5-53
⑤ Monitoring (digital)
21093CD66M
21093CD66N 21093CD66P
· The switch status or output status can be confirmed by this menu.

· The activated switch or output pilot lamps are light ON.
⑥ Operating hours
21093CD66Q
21093CD66R
· The operating hour of each mode can be confirmed by this menu.
5-54
(4) Management
① Maintenance information
21093CD67
21093CD67A
21093CD67Q 21093CD67R
21093CD67S 21093CD67T
· Alarm( ) : Gray - Normal

Yellow - First warning
Red - Second warning
· Replacement : The elapsed time will be reset to zero (0).
· Change interval : The change or replace interval can be changed in the unit of 50 hours.
· OK : Return to the item list screen.
· Change or relpace interval
No Item Interval
1 Engine oil 250
2 Final gear oil 1000
3 Swing gear oil 1000
4 Hydraulic oil 5000
5 Pilot line filter 1000
6 Drain filter 1000
7 Hydraulic oil return filter 1000
8 Engine oil filter 250
9 Fuel filter 500
10 Pre-filter 500
11 Hydraulic tank breather 250
12 Air cleaner (inner) 500
13 Radiator coolant 2000
14 Swing gear pinion grease 1000
5-55
② Machine security
21093CD67C
21093CD67D 21093CD67E
· ESL mode
- ESL : Engine Starting Limit
- ESL mode is desingned to be a theft deterrent or will
prevent the unauthorized operation of the machine.
- If the ESL mode was selected Enable, the password will
be required when the start switch is turned ON.
21093CD67EE
- Disable : Not used ESL function
Enable (always) : The password is required whenever the
operator start engine.
Enable (interval) : The password is required when the oper-
ator start engine first. But the operator
restarts the engine within the interval
time, the password is not required.
The interval time can be set maximum 4 21093CD67H
hours.
21093CD67U Enter the current password 21093CD67V
· Password change
- The password is 5~10 digits.
Enter the new password 21093CD67VV
21093CD67X 21093CD67XX
The new password is stored in the MCU. Enter the new password again
5-56
③ Machine Information
21093CD67F
21093CD67G
· This can confirm the identification of the cluster, MCU, engine and machine.
④ A/S phone number
21093CD67J
21093CD67K 21093CD67L
21093CD67Z 21093CD67Y
⑤ Service menu
21093CD67M
21093CD67N 21093CD67P
Enter the password
21093CD67ZZ
· Power shift (standard/option) : Power shift pressure can be set by option menu.
· Hourmeter start : Operating hours since the machine line out can be checked by this menu.
· Replacement history : Replacement history of the MCU and cluster can be checked by this
menu.
· Update : Firm ware can be upgraded by this menu. (the USB port is located under the
cluster)
5-57
(5) Display
① Display item
21093CD68
21093CD68A 21093CD68W
21093CD68B 21093CD68E
Center display
Center display
· The center display type of the LCD can be selected by this menu.
· The engine speed or each of the tripmeter (A,B,C) is displayed on the center display.
② Clock
21093CD68C
21093CD68D
· The first line's three spots "**/**/****" represent Month/Day/Year each.

· The second line shows the current time. (0:00~23:59)
5-58
③ Brightness
21093CD68F
21093CD68G 21093CD68H
Manual (1st~10th step)
21093CD68J 21093CD68K
Auto (day/night)
※ If "Auto" is chosen, brightness for day and night can be differently set up. Also by using the
bar in lower side, users can define which time interval belongs to day and night.
(in bar figure, gray area represents night time while white shows day time)
④ Unit
21093CD68L
21093CD68M 21093CD68N
· Temperature : ˚C ↔ ˚F
· Pressure : bar ↔ MPa ↔ kgf/cm2
· Flow : lpm ↔ gpm
· Date format : yy/mm/dd ↔ mm/dd/yy ↔ dd-Mar-yy
⑤ Language
21093CD68R
21093CD68S 21093CD68T
· User can select preferable language and all displays are changed the selected language.
5-59
⑥ Screen type
21093CD68U
21093CD68V 21093CD68W
A Type Standard
21093CD68Y
B Type 21093CD68X Option
(6) Utilities
① Tripmeter
21093CD69
21093CD69A 21093CD69B
· Maximum 3 kinds of tripmeters can be used at the same time.

· Each tripmeter can be turned on by choosing "Start" while it also can be turned off by
choosing "Stop".
· If the tripmeter icon is activated in the operation screen, it can be controlled directly there.
② DMB
21093CD69C
21093CD69D 21093CD69E
· DMB select : TV channel can be selected by this menu.

· DAB select : Audio channel can be selected by this menu.
· Channel scan : This menu can be used other region for TV/Audio.
· Exit : Exit DMB menu
5-60
③ Entertainment
· Play MP4 or codec file of external hard disk through USB port.
· The USB port is located under the cluster.
21093CD69F
21093CD69G
④ Camera setting
21093CD69J
21093CD69K 21093CD69L
· Three cameras can be installed on the machine.

· The display order can be set by this menu.
21093CD69M 21093CD69N
· If the camera was not equipped, this menu is not useful.

· In the operation screen, if the ESC/CAM switch is pushed, the first ordered display camera
will be viewed.
· Turnning the select switch in clockwise direction, the next ordered will be shown and in
counter-clockwise direction, the previously ordered will be shown.
· Push the select switch, the displayed screen will be enlargement.
⑤ Message box
· The history of the machine operating status can be checked by this menu.
21093CD69Q
21093CD69R
5-61
■ MONITORING SYSTEM (CLUSTER TYPE 2)
1. OUTLINE
Monitoring system consists of the monitor part and switch part.
The monitor part gives warnings when any abnormality occurs in the machine and
informs the condition of the machine.
Various select switches are built into the monitor panel, which act as the control portion of
the machine control system.
2. CLUSTER
1) MONITOR PANEL
LCD main operation display

(See page 5-63)
Warning lamp Pilot lamp

(See page 5-69) (See page 5-69)
3009SH5MS30
5-62
2) LCD main operation display
Default screen
screen screen
Option screen 1 Time display
2 2
1 1 2 RPM display
4
4
5
3 Hydraulic oil temperature gauge
3 3
5 4 Fuel level gauge
1607A3CD02A 1607A3CD02B 5 Engine coolant temperature gauge
(1) Time display

① This displays the current time.
※ Refer to the page 5-67 to set time for details.
1607A3CD02C
(2) RPM display

① This displays the engine rpm.
1607A3CD02C
(3) Hydraulic oil temperature gauge
12th step
① This gauge indicates the temperature of hydraulic oil in 12 step
gauge.
·1st step : Below 30˚C (86˚F)
·2nd~10th step : 30-105˚C (86-221˚F)
1st step ·11th~12th step : Above 105˚C (221˚F)
1607A3CD02D
② The gauge between 2nd and 10th steps illuminates when
operating.
③ Keep idling engine at low speed until the gauge between 2nd
and 10th steps illuminates, before operation of machine.
④ When the gauge of 11th and 12th steps illuminates, reduce
the load on the system. If the gauge stays in the 11th~12th
steps, stop the machine and check the cause of the problem.
(4) Fuel level gauge
1st step ① This gauge indicates the amount of fuel in the fuel tank.
② Fill the fuel when the 1st step or fuel icon blinks in red.
※ If the gauge illuminates the 1st step or fuel icon blinks in
1607A3CD02E
(5) Engine coolant temperature gauge
12th step
① This gauge indicates the temperature of coolant in 12 step
gauge.
·1st step : Below 30˚C (86˚F)
·2nd~10th step : 30-105˚C (86-221˚F)
1st step
·11th~12th step : Above 105˚C (221˚F)
1607A3CD02F ② The gauge between 2nd and 10th steps illuminates when
operating.
③ Keep idling engine at low speed until the gauge between 2nd
and 10th steps illuminates, before operation of machine.
④ When the gauge of 11th and 12th steps illuminates, turn OFF
the engine, check the radiator and engine.
5-63
3) Warning
arning of main operation screen
(1) Warning display
① Engine coolant temperature
- This lamp blinks and the buzzer sounds
when the temperature of coolant is over
the normal temperature 105˚C (221˚F).
- Check the cooling system when the lamp
blinks.
② Fuel level
when the level of fuel is below 69ℓ (18.2
U.S. gal).
- Fill the fuel immediately when the lamp
blinks.
③ Hydraulic oil temperature
- This warning lamp operates and the
buzzer sounds when the temperature of
hydraulic oil is over 105˚C (221˚F).
- Check the hydraulic oil level when the
lamp blinks.
- Check for debris between oil cooler and
radiator.
④ All gauge
when the all gauge is abnormal.
- Check the each system when the lamp
blinks.
⑤ Communication error
- Communication problem between MCU
and cluster makes the lamp blinks and
the buzzer sounds.
- Check if any fuse for MCU burnt off.
If not check the communication line
between them.
(2) Pop-up icon display
No Switch Selected mode Interval No Switch Selected mode Interval
1 Work mode General work 3 Auto Light ON

switch mode deceleration
switch
Heavy duty Light OFF
work mode
2 Power mode High power 4 Travel speed Low speed

switch work mode control
switch
Standard power High speed
work mode
5-64
4) LCD
1 : LCD
SYSTEM MENU
: Escape,
1
Monitoring Diagnosis Management
2
Settings Display User Mode
Return to the previous menu
3 : Down / Left Direction
4 : Up/Right Direction
: Select (enter)
5
2 Activate the currently chosen item
4
3 5
2209S3CD05
(1) Main menu

1 2 3 4
1 : Menu information
: Monitoring
2
- Equipment, Switch, Output
: Diagnosis
3
- Current error, Recorded error
5 6 7 4 : Maintenance
2507A4OP94
: Settings
5 - Time set, Dual mode
- System lock (reserved)
: Display
6
- Operation skin, Brightness, Language
7 : User mode
5-65
(2) Display map
① Monitoring
② Diagnosis
a. Protocol type 1
(Error display)
(Recorded error delete)
5-66
b. Protocol type 2
- If there are more than 2 error codes, each one can be displayed by pressing or switch
respectively.
- 3 error codes (①SPN200200, ②FMI06, ③SPN6789, ④FMI04, ⑤345) display.
① ② ⑤ No change
① ③ ④
① ③ ③
③ Maintenance
④ Setting
a. Time set
: Adjusting
: Setting
b. System lock - Reserved
5-67
c. Dual mode
- Changing the MCU mode
⑤ Display
a. Operation skin
b. Brightness
c. Language
⑥ User mode
Usermode(U) is not selected.
: Adjusting : Adjusting : Adjusting

: Setting : Setting : Setting
5-68
5) Warning
arning and pilot lamp
(1) Engine oil pressure warning lamp
① This lamp blinks and the buzzer sounds after starting the
engine because of the low oil pressure.
② If the lamp blinks during engine operation, shut OFF engine
immediately. Check oil level.
21073CD07
(2) Air cleaner warning lamp

① This lamp blinks and the buzzer sounds when the filter of air
cleaner is clogged.
② Check the filter and clean or replace it.
21073CD08
(3) CPU controller check warning lamp

① If any fault code is received from MCU, this lamp blinks and the
buzzer sounds.
② Check the communication line between MCU and cluster.
21073CD10
(4) Battery charging warning lamp

① This lamp blinks and the buzzer sounds when the starting
switch is ON, it is turned OFF after starting the engine.
② Check the battery charging circuit when this lamp blinks during
engine operation.
21073CD13
(5) Overload warning lamp

① When the machine is overload, the overload warning lamp
blinks during the overload switch is ON.
21073CD15
5-69
(6) Power max pilot lamp
① The lamp will be ON when pushing power max switch on the LH
RCV lever.
21073CD11
(7) Decel pilot lamp

① Operating auto decel or one touch decel makes the lamp ON.
② The lamp will be ON when pushing one touch decel switch on
the LH RCV lever.
21073CD17
(8) Warming up pilot lamp

30˚C (86˚F).
② The automatic warming up is cancelled when the engine cool-
ant temperature is above 30˚C, or when 10 minutes have
passed since starting.
21073CD18
(9) Preheat pilot lamp

Turning the start key switch ON position starts preheating in cold
weather.
Start the engine as this lamp is OFF.
21073CD12
5-70
3. E
1. S
2. O
CN-5
1 CR-35
2W
2 30
0.8WOr 87a 87 85
86
3
2WR
minutes.
87
4 0.8B
85
ELECTRIC
5
87a 30 86
POWER RY
mechanism.
6
OPERATION
PERATION
6
5
ST C
CS-2
3) Current : 15 A
7
GROUP 15 F
6
8 2W
5 1
SPECIFICATION
PECIFICATION
3 9 CN-36
2 2W
BR ACC
1 4 17 2 30A
2W IG POWER
2) Power : 350±50 W
138
1
H
4 3
FUEL
18 CS-74B ROOM LAMP/CASSETTE 10A
MASTER SW
LECTRIC CIRCUIT
2
1.2R
0, I
2 19 30A
1.2R MCU
2WR
1 3
START KEY SW
20 30A
H 0 I
2W START KEY 4
21 20A
AIR CON/HEATER
22 5
10A
1) Operating voltage : 24±4 V
WIPER
5R 146
23 6
CLUSTER 10A
according to fuel temperature.

24 7
CLUSTER 10A
31 8
MCU CONT. 20A
32 9
MCU EPPR 20A
reduce the current as low as 1.5 A.

33 10
SWITCH PANEL 10A
34 11
CASSETTE 10A
CN-125A 35 12
0.8W SPARE 10A
BATTERY POWER 1 36 13
1.2R 20A
KEY "IG" 2 37 CONVERTER
14
NC 3 CN-51 WORK LAMP 30A
38
RX232(1)-TX 4 1.2B 15
39 BATTERY POWER 24V(+) 1 CABIN LAMP(OPTION) 30A
RX232(1)-GND 5 16
UEL WARMER SYSTEM
42 MCU(CLUSTER TYPE 1) WIPER 10A

RX232(2)-RX 6 17
RX232(2)-TX 7 43 HEAD LAMP 20A
RMS
CN-50
1.2B 18
5-71
RX232(2)-GND 8 44 BATTERY POWER 24V(+) 7 FUEL HEATER 30A
warmer and engine may be started in 1~2
automatically controlled without thermostat
So, fuel is protected from overheating by this

warmer heater senses the fuel temperature to
3) If the fuel starts to flow, ceramic-disk in the fuel
2) At the first state, the 15 A current flows to the fuel
1) T h e c u r r e n t o f f u e l w a r m e r s y s t e m i s
2L
RX232(1)-RX 9 19
45 MCU(CLUSTER TYPE 2) START,STOP 30A
NC 10 20
46 HORN 10A
MAIN GND 11
145 5W
21
47 20A
MAIN GND 12 AC& HEATER
48 22
SAFETY SOL 10A
57 23
OPTION 20A
58 24
SOLENOIDE 20A
59 25
CN-52 CIGAR 20A
60 26
FUEL WARMER RY 12 OPTION(BEACON) 20A
27
MCU(CLUSTER TYPE 1) TRAVEL SOL 20A
28
CN-50 PRE-HEAT 10A
29
FUEL WARMER RY 6 FUEL P/P 20A
CR-1
30
MCU(CLUSTER TYPE 2) ALT 10A
31
BATT RY
CR-46
FUSE BOX
30
85 87 87a
86
CS-74A
60R
87
5R
85 1
86 30
1
2
1
2
87a 5R
CN-60
CN-95
2
CS-74
FUEL WARMER RY
MASTER SW
CN-96
(12VX2)
FUSIBLE LINK
5R
5R
5W
BATTERY
5W
1
2
60B
3
Prefilter
FUEL WARMER
Fuel warmer
2507A5MS12
3309S5MS32
Group 1 Before Troubleshooting -------------------------------------------------------------------------------------- 6-1

Group 2 Hydraulic and Mechanical System ------------------------------------------------------------------- 6-4
Group 3 Electrical System ----------------------------------------------------------------------------------------------- 6-24
Group 4 Mechatronics System ---------------------------------------------------------------------------------------- 6-56
GROUP 1 BEFORE TROUBLESHOOTING
1. INTRODUCTION
When a trouble is occurred in the machine, this section will help an operator to maintain the machine
with easy.
The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and
Mechatronics system. At each system part, an operator can check the machine according to the
troubleshooting process diagram.
※ Before carring out troubleshooting procedure, check monitoring menu in the cluster.
Hydraulic &
Mechanical part GROUP 2
Electrical part GROUP 3
Mechatronics
Troubles occur part GROUP 4
Fault codes HCESPN 3digit

displayed on See page
+ FMI 1 digit 5-25
monitor display (machine)
(Cluster type 1)
Fault codes 2 digit See page
displayed on
monitor display (machine) 5-29
(Cluster type 2)
6-1
2. DIAGNOSING PROCEDURE
To carry out troubleshooting efficiently, the following steps must be observed.
STEP 1. Study the machine system

Study and know how the machine is operating,
how the system is composing, what kinds of
function are installed in the machine and what
are specifications of the system components by
the machine service manual.
Especially, deepen the knowledge for the
related parts of the trouble.
13031SH02
STEP 2. Ask the operator

Before inspecting, get the full stor y of
malfunctions from a witness --- the operator.
1) How the machine is used and when it is
serviced?
2) When the trouble was noticed and what
work the machine was doing at that time?
3) What is the phenomenon of the trouble?
Was the trouble getting worse, or did it
come out suddenly for the first time?
4) Did the machine have any troubles
previously? If so, which par ts were
13031SH03
repaired before.
STEP 3. Inspect the machine

Before starting troubleshooting, check the
machine for the daily maintenance points as
shown in the operator's manual.
And also check the electrical system including
batteries, as the troubles in the electrical system ON THE
INSPECTION
such as low battery voltage, loose connections
and blown out fuses will result in malfunction of
(210-7) 6-2(3)
the controllers causing total operational failures
of the machine.
6-2
STEP 4. Inspect the trouble actually on the
machine
In case that some trouble cannot be confirmed,
obtain the details of the malfunction from the
operator.
Also, check if there are any in complete
connections of the wire harnesses are or not.
(210-7) 6-3(1)
STEP 5. Perform troubleshooting

According to where the trouble parts are
located, hydraulic & mechanical system part or
electrical system part or mechatronics system
part, perform troubleshooting the machine refer
to the each system part's troubleshooting
process diagram.
13031SH05
STEP 6. Trace a cause

Before reaching a conclusion, check the most
suspectible causes again. Try to trace what
the real cause of the trouble is.
Make a plan of the appropriate repairing

procedure to avoid consequential malfunctions.
(210-7) 6-3(3)
6-3
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM
1. INTRODUCTION
1) MACHINE IN GENERAL
(1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused,
entailing a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look
for the cause based on the troubleshooting principle and perform maintenance and adjustment to
prevent major failure from occurring. Keep in mind that a fault results from a combination of
different causes.
(2) The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the coming troubleshooting and repair.
(3) When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.
(4) Ask user or operator the following.
① Was there any strange thing about machine before failure occurred?
② Under what conditions did the failure occur?
③ Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
① Check oil and fuel level.
② Check for any external leakage of oil from components.
③ Check for loose or damage of wiring and connections.
2) MACHINE STATUS MONITORING ON THE CLUSTER (CLUSTER TYPE 1)
(1) The machine status such as the engine rpm, oil temperature, voltage and pressure etc. can be
checked by this menu.
Note 6
Note 3
Note 4
Note 5
Note 2
Note 1
Analog 1
Analog 1 Analog22
Analog 3009SH6HS01
(2) Specification
No. Description Specification
Note 1 Pilot pump pressure 40+20 bar
Note 2 Swing pilot pressure 0~40 bar
Note 3 Boom up pilot pressure 0~40 bar
Note 4 P1 pump control pressure 0~25 bar
Note 5 P2 pump control pressure 0~25 bar
Note 6 Pump 1 pressure 350 bar
6-4
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION
Cause Remedy
YES
Coupling element Disassemble
is broken. and repair.
Remove dust
plug under engine
flywheel and
YES
check if rubber Replace hub or
pieces or particles retighten
are not present. Coupling hub setscrew.
spline is worn or
NO hub fastening
setscrew is slack.
If hydraulic pump or engine is
suspected as a culprit refer to this
NO
manual "Structure and function".
6-5
2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL
Cause Remedy
NO
Replenish
specified oil to
the standard
Is oil level in Abnormal noise level.
hydraulic oil YES comes out of YES
Hydraulic pump is Disassemble
tank within hydraulic pump
standard level? broken. and repair.
Do not hydraulic Abnormal noise

pump and pump YES comes out of YES
connections pump See item 1).
YES
make abnormal connection at page 6-5
noise?
Is pilot pump
pressure within ⓐ
NO standard level?
See Note 1
YES
Clean pilot
Is pilot piping piping interior or
YES clogged or is oil
repair piping.
leakage present
on pilot piping?
RCV and safety Disassemble
NO
solenoid valve is and repair.
ⓐ faulty.
YES
Pilot relief valve in Repair or
gear pump is replace.
Is gear pump
faulty.
NO delivering oil?
Gear pump is Disassemble

NO
broken. and repair.
6-6
3. HYDRAULIC SYSTEM
1) HYDRAULIC OIL IS CLOUDY
Cause Remedy
YES
Water is mixed. Put hydraulic oil
still, separate
Drop hydraulic oil water and
sample on hot dispose it or
plate and check if replace hydraulic
foams come up. oil.
NO
Air is intruded. Check suction
line and return
line and eliminate
the air intruding
source.
2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY
Cause Remedy
NO
Replenish
specified oil to
the standard
Is hydraulic oil level.
volume proper? YES
Oil cooler clogged. Clean oil cooler.
Bypass check Replace
Is oil cooler clogged
and is bypass check valve is defective.
YES valve always open? YES ⓐ
Is fan belt
NO tension proper?
Adjust belt
NO tension or
replace belt.
Is not the set
pressure of main YES Readjust set
relief, port relief pressure.
ⓐ and travel relief
Is main relief
valve lower than
valve used very YES Reduce load.
the standard NO often?
level?
6-7
3) CAVITATION OCCURS WITH PUMP
Cause Remedy
NO Replenish
specified oil to
the standard
Is hydraulic oil level.
volume proper? YES
Replace oil with
one of proper
Is not viscosity viscosity.
of hydraulic oil
YES YES
too high? Clean suction
Is not suction strainer.
NO strainer clogged? Is not air intruding
from pump Check for air
NO intrusion in
suction line?
suction line and
retighten or
replace parts.
4) HYDRAULIC OIL IS CONTAMINATED
Cause Remedy
YES Replace
Has not hydraulic hydraulic oil to be
oil passed specified.
specified replace-
ment hours? Has return filter
NO
been replaced at Flush with
NO proper intervals?
hydraulic oil and
replace return
filter.
6-8
4. SWING SYSTEM
1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE
Cause Remedy
NO
Replenish
Does safety YES
ⓐ specified oil to the
YES solenoid valve
standard level.
operation
Is gear pump pilot normal? Safety solenoid Repair or replace.
NO
pressure within valve faulty or not
YES standard level?
Is oil in hydraulic operated.
YES tank within
See Note 1 Gear pump faulty. Repair or replace.
standard level? NO
YES
Are broken pieces Pump connection Disassemble and
of coupling present coupling is broken. repair.
ⓐ when dust plug
under engine fly NO
Are attachment wheel is removed? Is main relief Hydraulic pump is Disassemble and
NO valve faulty?
and travel out of order. repair.
motions
impossible at all? NO
Does swing Swing control valve Disassemble and
YES
control valve spool is stuck. repair.
Is MCV swing spool move?
YES pilot pressure YES
ⓑ
within standard See Note 5
level?
ⓒ
Is LH travel See Note 2 NO
NO function normal?
Does not symptom
change when front YES
and rear pump Hydraulic pump is Disassemble and
NO
discharge hoses broken. repair.
are exchanged?
YES
Swing parking Disassemble and
brake release valve repair.
Is swing parking is broken.
ⓑ brake release
valve faulty? YES
Swing reduction Disassemble and
Does swing unit is broken. repair.
NO motor rotate?
Swing motor is Disassemble and
NO
broken. repair.
YES
Pilot relief valve in Disassemble and
NO Is gear pump gear pump is faulty. repair or replace.
delivering oil?
Gear pump is out of Disassemble and
NO
Is gear pump pilot order. repair.
ⓒ pressure within
standard level? YES
Is there oil Clean pilot piping
See Note 1 interior or repair
leakage from
YES pilot piping or is it piping.
clogged? RCV is broken. Disassemble and
NO
repair.
6-9
2) SWING SPEED IS LOW
Cause Remedy
YES
Swing port relief Disassemble and
YES Does swing spool valve is faulty. repair or replace.
move?
Swing control valve Disassemble
Is MCV pilot NO
spool is stuck. and repair.
pressure same
on LH and RH YES Clogged or oil
sides? Clean pilot piping
leak. interior or repair
See Note 2 Is pilot piping
Single direction clogged or is it piping.
NO leaking oil?
Is the trouble in RCV or shuttle Disassemble
one direction or NO
valve is faulty. and repair.
in both direction? YES
ⓐ
YES Does swing spool
Both directions move?
YES Is MCV pilot Swing spool is Disassemble
pressure within NO
Is Arm speed See Note 5 stuck. and repair.
standard level?
within standard ⓑ
value? See Note 2 NO
ⓒ
NO
Is swing motor's NO
ⓐ drain rate within Swing motor is Disassemble
standard value? broken. and repair.
Check that pilot
YES piping is clogged NO
or oil is leaking RCV or shuttle Disassemble
from it? valve is faulty. and repair.
Clogged or oil leak. Clean pilot piping

Is gear pump pilot interior or repair
ⓑ pressure within piping.
standard level?
Pilot relief valve
YES
See Note 1 in gear pump is Disassemble and
Is gear pump defective. repair or replace.
NO delivering oil?
NO
broken. and repair.
NO
Main relief valve Main relief valve
faulty. pressure resetting
or repair.
Is main relief Does the symptom YES Hydraulic pump Disassemble
ⓒ valve setting change when front
YES is broken. and repair.
pressure normal? and rear pump
discharge hoses
See Note 7
are exchanged? NO Shuttle valve is Repair or replace.
Is MCV pilot faulty.
YES pressure within
standard level? YES
Is gear pump Pilot relief valve Repair or replace.
See Note 2 output pressure is faulty.
NO within standard
level? Gear pump is Repair or replace.
See Note 1
NO
faulty.
6-10
3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION
Cause Remedy
YES
Does symptom Swing port relief Disassemble
change when LH
YES valve is faulty. and repair.
and RH port
relief valves are
exchanged? NO Shuttle valve is Disassemble
YES Does swing control faulty. and repair.
valve spool move?
Is MCV pilot Swing control valve Disassemble

NO
pressure same spool is stuck. and repair.
for LH and RH?
YES
See Note 2
Check if pilot RCV is faulty. Disassemble
piping is clogged and repair.
NO or does have oil
leakage. Clogged or oil
NO leak.
Clean pilot piping
interior or repair
piping.
4) MACHINE SWINGS BUT DOES NOT STOP
Cause Remedy
YES
Pilot relief valve is Disassemble
faulty. and repair or
YES Is MCV pilot YES Is gear pump pilot
pressure within pressure within replace.
standard value? standard level?
See Note 2 See Note 1 Gear pump is Disassemble
NO
broken. and repair.
YES Does swing spool
move?
RCV is faulty. Disassemble
NO
and repair.
Is swing control
valve's return
spring normal? Swing spool is Disassemble
NO
stuck. and repair.
Return spring is Disassemble

NO
faulty. and replace.
6-11
5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE
Cause Remedy
YES
ⓐ
YES Is swing shuttle
valve normal?
Shuttle valve is Disassemble
NO
faulty. and replace.
YES Is brake spring
normal?
Is return spring
of swing spool Brake spring is Disassemble
NO
normal? faulty. and replace.
Return spring of Disassemble

NO
swing control and replace.
valve is faulty.
YES
Is drain rate of Swing port relief Disassemble
YES swing motor valve is faulty. and repair or
within standard replace.
Is swing relief value? Swing motor is Disassemble
pressure within NO
ⓐ broken. and repair.
standard level?
SPEC : 300±10kgf/cm2 Adjust swing
NO
relief valve
pressure or
replace swing
relief valve.
6-12
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE
Cause Remedy
YES
Does ⓐ
YES counterbalance
spool move lightly
by hand? Counter spool is
Is travel brake Disassemble
NO
YES valve pressure stuck. and repair or
within standard replace.
level? Does the symptom
change when
relief valves in YES
Relief valve built Disassemble
NO travel motor are
Has travel spool exchanged? in travel motor is and repair.
YES
changed over faulty.
positively?
YES Control system is Disassemble
defective. inspect and
Does travel spool
repair.
NO move?
NO
Travel spool is Disassemble
stuck. and repair.
Is bucket or arm
operation YES Travel reduction Disassemble
possible? Do not metallic
unit is faulty. and repair.
particles come
ⓐ out of drain port
in travel
reduction unit? Travel motor is Disassemble
NO
out of order. and repair.
Does the symptom
NO
change when front YES
and rear pump Hydraulic pump is Disassemble
Does the discharge hoses
symptom change broken. and repair.
are exchanged?
when LH/RH
NO
travel relief valves
are exchanged?
YES
Travel relief Disassemble
valves are faulty. and repair or
replace.
6-13
2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES
Cause Remedy
YES
Brake valve is Disassemble
Do LH and RH
travel speeds defective. and repair or
YES change when LH replace.
YES
and RH travel Does the symptom Relief valve built Disassemble
brake valves are change when in travel motor is and repair.
exchanged? relief valves in
faulty.
NO LH and RH
YES Has travel spool travel motors are
changed over exchanged? ⓐ
positively? NO
YES
Control system is Disassemble,
faulty . inspect and
Does spool move? repair.
Is the lower NO
speed (bucket or
arm) within See Note 5, 6 Control valve Disassemble
NO
standard level? spool is stuck. and repair.
YES
Travel relief valve Disassemble
Do LH and RH is faulty. and repair or
travel speeds Does the symptom replace.
change over when change when
NO travel relief valves YES front and rear YES
pump discharge Hydraulic pump is Disassemble
are exchanged?
Is external pilot hoses are broken. and repair.
pressure within exchanged?
NO
standard level?
External pilot Disassemble
NO
piping is clogged and clean.
or oil is leaking
Does travel speed from it.
change when
YES parking brake YES
spring in the Travel motor's Disassemble
travel motor is parking brake is and clean pilot
Is drain rate of removed? not released piping.
ⓐ travel motor within
standard level? properly.
Travel motor is Disassemble

NO
faulty. and repair.
6-14
3) MACHINE DOES NOT STOP ON A SLOPE
Machine is pulled forward as sprocket rotates during digging operation.
Cause Remedy
None Is parking brake YES
friction plate Friction plate is Disassemble
YES Check if parking worn? faulty. and repair.
brake pilot line is
clogged.
Clogged Disassemble
and clean pilot
Is drain rate of piping.
Is travel brake YES NO
travel motor
pressure within Travel motor is Disassemble
within standard
standard level? defective. and repair.
value?
SPEC : 15.7kgf/cm2
Brake valve is Disassemble

NO
faulty. and repair or
replace.
4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE
YES
Cause Remedy
Inspect according
to the procedure
"Travel does not
function at all on
one side."
However, a case
where both LH
and RH travel
motions are
disabled is
Is bucket or arm
operation extremely seldom
possible? statistically.
OK
Disassemble both faulty. and repair.
OK travel relief valves
Remove dust and inspect for
plug under engine any fault.
OK flywheel and Travel relief valve Disassemble
check that there is Faulty is faulty. and repair or
no coupling
replace.
element particles.
Check oil volume Particles present. Coupling at pump
in hydraulic oil connection is Disassemble
NO tank. broken. and repair.
Short Replenish
hydraulic oil.
6-15
5) TRAVEL ACTION IS POWERLESS (travel only)
Cause Remedy
YES
ⓐ
Is travel motor's
YES
drain rate within
standard level?
Is travel brake Travel motor is Disassemble
YES NO
pressure within faulty. and repair.
standard level?
Is travel relief
valve pressure Travel brake valve Disassemble
NO
within standard is defective. and repair or
level?
replace.
NO
Travel relief valve Disassemble
is faulty. and repair or
replace.
YES
Hydraulic circuit Disassemble
Does parking that releases and clean.
brake piston travel parking
Increases move lightly by
Remove parking brake is clogged
brake spring in hand?
with dirt.
travel motor,
draw out piston Parking brake Disassemble
ⓐ NO
completely, refit piston in travel and repair.
cover and check motor is stuck.
if travel power
changes. Remains
unchanged Travel reduction Disassemble
unit is defective. and repair.
6) MACHINE RUNS RECKLESSLY ON A SLOPE
Cause Remedy
Travel brake valve
(counterbalance Disassemble
valve) is faulty. and repair or
replace.
6-16
7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL
AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME
Cause Remedy
YES
Normal.
YES Is straight spool

normal?
Straight spool is Repair or

Is pilot pressure NO
for travel straight faulty. replace.
spool within
standard level? YES
Remove dirt on
signal orifice.
Is signal orifice
YES Is pilot relief NO
NO clogged? Pilot relief valve is Disassemble
valve normal?
defective. and repair or
Is gear pump
replace.
NO delivering oil?

NO
broken. and repair.
6-17
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL
Cause Remedy
YES
Does the Port relief valve is Disassemble
YES symptom change faulty. and repair or
when port relief replace.
valve is replaced
with other valve? NO ⓐ
YES Is MCV pilot
pressure within
standard level?
Inspect if pilot
See Note 3 piping is clogged OK
RCV is faulty. Disassemble
NO or oil is leaking
YES Are other from the piping. and repair.
attachments
operatable?
YES
Is gear pump
pilot pressure YES Is gear pump faulty. and repair or
NO within standard delivering oil? replace.
level? Gear pump is Disassemble
See Note 1 NO
broken. and repair.
Are LH/RH travel
operations OK
possible? Hydraulic pump is Disassemble
Disassemble broken. and repair.
YES main relief valve
Remove dust plug and check if it is
under engine not irregular.
OK flywheel and
Main relief valveDisassemble
Faulty
check if coupling is defective. and repair or
element particles replace.
Inspect oil are not present. Coupling at pump Disassemble
Particles present
NO
volume in
hydraulic oil tank. connection is and repair.
broken.
Short Replenish
hydraulic oil.
YES
Cylinder interior is Disassemble
Does control broken. and repair.
ⓐ valve spool
move?
MCV spool is Disassemble
See Note 5, 6 NO
stuck. and repair.
6-18
2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal.
YES
Are other ⓐ
YES attachment
Is combination speeds within
Is speed low only of oil streams standard levels? NO ⓑ
in composite YES
normal at boom YES
operation? up and at arm Does spool of flow Flow summation Disassemble
extrusion? summation check check valve is and repair.
NO valve move lightly stuck.
Are LH/RH travel by hand?
NO speeds within NO
standard levels?
YES
Are both LH/RH faulty. and repair.
travel speeds YES ⓒ
NO
low? Is MCV pilot
pressure within
NO
standard? ⓓ
NO
See Note 3
OK
Does the Port relief valve is Disassemble
symptom change faulty. and repair or
YES
when port relief
valve is replaced replace.
Does control with other valve? Cylinder is faulty. Disassemble
YES valve spool NO
and repair.
move ?
See Note 7
NO MCV spool is Disassemble
Is MCV pilot
ⓐ pressure within stuck. and repair.
standard level?
Is not MCV pilot YES
Clean pilot
See Note 3
pressure piping piping interior or
clogged or is not
NO
there oil repair piping.
leakage? RCV is defective. Disassemble
NO
and repair.
YES
Is pilot pressure NO faulty. and repair or
ⓑ Is gear pump
within standard
delivering oil? replace.
level?
NO
See Note 1
broken. and repair.
AIs engine NO
ⓒ revolution within Adjust engine
standard level? revolution.
YES
Clean orifice in
control valve.
Is not orifice in
ⓓ main control YES
valve clogged? Is pilot piping Clean pilot
clogged or is oil piping interior or
NO leaking from the repair piping.
piping? Is RCV normal? RCV is faulty. Disassemble
NO NO
and repair.
6-19
3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS
Cause Remedy
YES
Port relief valve is Disassemble
Does the symptom faulty. and repair or
change when port
Normal
relief valve is replace.
YES
replaced with ⓐ
normal value? Is control valve
return spring
YES
Is not hydraulic NO
normal?
oil temperature Control valve's Disassemble
high? NO
return spring is and replace.
faulty.
Is genuine Abnormally high. Locate the
hydraulic oil or cause of
equivalent being hydraulic oil
used?
temperature rise
and lower it to
proper level.
Replace with
NO
genuine
hydraulic oil or
equivalent.
OK
Pressure Disassemble
Disassemble and tightness and repair.
inspect load between control
YES
check valve in
MCV and check valve casing and
for any fault. spool is poor.
Is cylinder Contact surface Disassemble
internal leakage Abnormal
ⓐ within standard between poppet and repair.
level? and seat is poor.
Cylinder is faulty. Disassemble

NO
and repair.
6-20
4) BOOM, ARM OR BUCKET POWER IS WEAK
Cause Remedy
YES
Check according
Is cylinder to the procedure
YES internal leakage in Item "Speed is
within standard low".
level?
Is relief pressure
YES in port relief Cylinder is faulty. Disassemble
valve within NO
and repair.
standard level?
Is relief pressure
in main relief Port relief valve is Adjust pressure,
valve within NO
standard level? faulty. repair or replace.
See Note 7
Main relief valve Adjust pressure,
NO
is defective. repair or replace.
5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE
Cause Remedy
YES
Port relief valve is Disassemble
Does the defective. and repair or
YES
symptom change
when port relief replace.
YES
valve is replaced Cylinder interior is Disassemble
with other valve? Does control broken. and repair.
valve spool
Is MCV pilot NO move?
YES
pressure within MCV spool is Disassemble
standard level? See Note 5 NO
stuck. and repair.
Is RH travel RCV is faulty. Disassemble

NO
possible? and repair.
Does the YES

Main relief valve Adjust pressure,
symptom change is faulty. repair or
Does the
when main relief
NO valves are symptom change replace.
when hydraulic YES
exchanged? Hydraulic pump is Disassemble
NO pump's discharge
hoses are broken. and repair.
exchanged?
6-21
6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED
Cause Remedy
YES
Frictional noise
occurs between
the sliding faces
of boom
cylinder's oil
Is boom foot pin seal and boom
greased proper.
sufficiently?
※ Frictional
noise will
disappear if
they are kept
used.
Boom foot pin Supply grease

NO
has run out of to it.
grease. ※ If seizure is
in an initial
stage, supply
sufficient
grease.
If seizure is
in a grown
state, correct
it by paper
lapping or
with an oil
stone.
6-22
※ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE
1. Lower the bucket teeth to the ground with
bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.
29076TS01
2. Disconnect hose (A) from rod side of boom

cylinder and drain oil from cylinders and
hose. (put cups on piping and hose ends) A
(210-7) 6-20(2)
3. Raise bucket OFF the ground by retracting

the arm cylinder rod.
If oil leaks from piping side and boom
cylinder rod is retracted there is an internal
leak in the cylinder.
If no oil leaks from piping side and boom
cylinder rod is retracted, there is an internal
leak in the control valve.
29076TS01
6-23
GROUP 3 ELECTRICAL SYSTEM (CLUSTER TYPE 1)
1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.7, 8.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
Check voltage YES

Disconnection in Repair or replace
between CN-56
(3) and (5) wiring harness or (after clean)
Check voltage poor contact
Starting switch : ON between
Voltage : 20~32V between
NO CN- 5 (4) and (5)
CN-5-CN-56
Starting switch : ON
Voltage : 20~32V Disconnection in Repair or replace
NO
wiring harness or (after clean)
poor contact
between CN-5 (4)
-GND or fuse
No.7, 8
Check voltage
YES 20~32V
NO 0V
FUSE
CLUSTER NO.7
POWER(24V) 1 6
FUSE
POWER IG(24V) 5 5
NO.8
GND 3 4
CN-56 CN-5
3009SH6ES01
6-24
2. COMMUNICATION ERROR FLASHES ON THE CLUSTER (HCESPN 840, FMI 2)
·Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
YES Check voltage

between CN-56
(4, 8) and (3) Disconnection in Repair or replace
NO wiring harness or (after clean)
Check voltage Voltage : 2V poor contact
between between CN-56
CN-5 (1) and (2) (4, 8)-CN-5 (1, 2)
Voltage : 2V Defective MCU Replace
NO Disconnection in Repair or replace
poor contact
between CN-5 (1,
2)- CN-51(23, 33)
Check voltage
YES 2V
NO 0V
CLUSTER
GND 3 4 MCU
RS485 RX 8 2 23 RS485 TX
RS485 TX 4 1 33 RS485 RX
CN-51
CN-56 CN-5
3309S6ES02
6-25
3. BATTERY CHARGING WARNING LAMP LIGHTS UP
UP(Starting switch : ON)
Cause Remedy
YES
Defective MCU Replace
YES Check voltage
between CN-52
(27) and chassis Disconnection in Repair or replace
NO
Check voltage wiring harness or (after clean)
YES Voltage : 20~32V
between CN-3 poor contact
(3) and chassis between CN-52
(27)-CN-3 (3)
Voltage : 20~32V
Check voltage NO wiring harness or (after clean)
(2) and chassis between CN-3 (3)-
CN-74 (1)
Engine : Running
Voltage : 20~32V
Defective alternator Replace

NO
Check voltage
YES 20~32V
NO 0V
ALTERNATOR
B+
MCU
G
1 P
27 3 2 L
3 ~
U
3 FI
4 NC
CN-74
CN-52 CN-3
3009S6ES01
6-26
4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
Coolant overheat Check engine
Resistance (110˚C±2˚C) cooling system
YES between CD-8
(1, 2) is in range
of 120~150Ω?
Defective temp Replace
Disconnect CD-8 NO
sensor
Does display go
off when
disconnect
CD-8?
Engine : Start YES
Short circuit in Repair or replace
Resistance wiring harness (after clean)
between CN-51
NO (13) and CN-52
(25) 0~1Ω?
Disconnect CN-51 NO
KEY OFF
Check Table
Temperature (˚C ) 0 25 50 80 95
Resistance (kΩ) 30~37 9.3~10.7 3.2~3.8 1.0~1.3 0.7~0.8
MCU
13
WATER TEMP SENDER
5 1 C
CN-51
6 2
CN-3 CD-8
25
CN-52
3009SH6ES04
6-27
5. WHEN AIR CLEANER WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
Clogged air filter or Check filter or
defective switch replace switch
Does display go
off when
disconnect YES
CD-10? Short circuit in Repair or replace
Starting switch : ON wiring harness (after clean)
Engine : Start Check resistance
between CD-10-
between CN-51
NO CN-51(29)
(29) and chassis
Starting switch : OFF
Disconnect CN-51
NO
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
MCU AIR CLEANER SWITCH
Pa
29
CD-10
CN-51
3009SH6ES05
6-28
6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
switch
Does display go
off when
disconnect YES
CD-18? Defective controller Replace
Engine : Start Check resistance
between CN-51
NO
(27) and chassis
Disconnect CN-51
NO
poor contact
between
CN-51(27)-CD-18
MCU ENGINE OIL PRESSURE SWITCH
27 1 Pa
CN-51 CN-2 CD-18
3009SH6ES06
6-29
7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
High temperature Check hydraulic
Resistance oil temperature
YES between CD-1 (105˚C±2˚C),
(1, 2) is in range
of 164~151Ω?
Does display go Starting switch : ON Defective temp Replace
Disconnect CD-1 NO
off when sensor
disconnect
CD-1? YES
Short circuit Repair or replace
Starting switch : ON Resistance between temp
Engine : Start between CN-51
sensor and MCU
NO (13) and CN-52
(24) 0~1Ω?
Starting switch : OFF NO
Disconnect CN-51
Check Table
Temperature (˚C ) ~ -30 ~ -10 ~0 ~ 40 ~ 70 ~ 80 ~ 90 ~ 100 105~
22.22 8.16 5.18 1.06 0.39 0.322 0.243 0.185 0.164
Resistance (kΩ)
~31.78 ~10.74 ~ 6.6 ~1.28 ~0.476 ~0.298 ~0.219 ~0.167 0.151
MCU
13
CN-51
HYDRAULIC OIL
TEMPERATURE SENDER
1 C
24 2
CD-1
CN-52 3009SH6ES07
6-30
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE (HCESPN 304,
FMI 3 or 4)
Cause Remedy
YES
poor contact
Is resistance between
YES between CN-51 CN-52-CD-8
(13) and CN-52
(25) over 2kΩ?
Starting switch : OFF YES
Does the gauge Disconnect CN-50 Defective MCU Replace
light up and Check resistance
down at lamp between CN-3
NO
check? (5) and (6)
Starting switch : ON Defective temp Replace
See Table NO
sensor
NO
Disconnection Replace
cluster
Check Table
Temperature (˚C ) 0 25 50 80 95
Resistance (kΩ) 30~37 9.3~10.7 3.2~3.8 1.0~1.3 0.7~0.8
MCU
13
WATER TEMP SENDER
5 1 C
CN-51
6 2
CN-3 CD-8
25
CN-52
3009SH6ES04
6-31
9. WHEN FUEL GAUGE DOES NOT OPERATE
OPERATE(HCESPN 301, FMI 3 or 4)
Cause Remedy
YES
Defective MCU or Replace
Check resistance cluster
YES between CN-51
(13) and CN-52
(26)
Starting switch : OFF Disconnection in Repair or replace
Check resistance Disconnect CN-51 NO
between fuel Spec : 50~600Ω wiring harness or
sender (1) and poor contact
(2) between fuel
Starting switch : OFF sender-MCU
Spec : 50~600Ω
See table
Defective fuel Replace
NO
sender
Check Table
Range Resistance (Ω) Range Resistance (Ω)
Full 50 5/12 400
11/12 100 4/12 450
10/12 150 3/12 500
9/12 200 2/12 550
8/12 250 1/12 600
7/12 300 Empty warning 700
6/12 350 - -
MCU
13
FUEL LEVEL SENDER

1
CN-51
2
CD-2
26
CN-52
3009SH6ES08
6-32
10. WHEN SAFETY SOLENOID DOES NOT OPERATE
short of fuse No.23.
Cause Remedy
YES
Hydraulic system Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
NO
Safety lever : ON-OFF
YES
Disconnect in Repair or replace
Check resistance
(1) - (2) YES between CN-4 between
(16) and chassis CN-4-CN-68
Voltage : 20~30V YES
Safety state Starting switch : OFF Disconnect in Repair or replace
Safety state
Spec : 0Ω
Disconnect CN-4 Check resistance poor contact
Check voltage
between CS-4 between
between CN-68 NO
NO (A)-(C) CN-4-CS-4
(2) and chassis
Safety lever : OFF Defective safety Replace
Safety switch : ON-0Ω
Starting switch : ON NO
Voltage : 20~30V
OFF-∞ switch

NO
wiring harness
between
CN-68 (2)-fuse
FUSE
NO.23
SAFETY SWITCH
B C A 14 SAFETY SOLENOID
B 15 2
A C 16 1
CS-4 CN-68
CN-4
21096ES10
6-33
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE (HCESPN 167, FMI 5 or 6)
Cause Remedy
YES
wiring harness or
Check resistance poor contact
YES
between CN-70 between CN-70-
(1) and (2) CN-52
Starting switch : OFF Defective solenoid Replace
Spec : 30Ω NO
YES Check fault code Disconnect CN-70
167 active?
YES
Defective hydraulic Check hydraulic
system system
Check voltage
Check if travel between CN-70
speed lamps( , NO (1) and (2)
) change when
pressing the travel Starting switch : ON Disconnection in Repair or replace
Spec : 20~30 V NO
speed switch on wiring harness or
Disconnect CN-70
the cluster poor contact
between CN-70-
fuse No. 25
YES
Check MCU
Y R G
NO
NO
FUSE
NO.25
MCU TRAVEL SOLENOID
3 1
CN-70
CN-52
3009SH6ES09
6-34
12. WHEN ENGINE DOES NOT START ( lights up condition)
short of fuse No. 1, 4, 20.
Cause Remedy
YES START KEY SW
Delective battery Replace CN-5
CS-2
H0 I
35 1
0, I
36 2
59 3 4
H
60
BR ACC
4 1
B
2
5 3
6
Check operation YES
ST C
5
Check voltage Defective magnet Replace 6
start motor
YES between starter of start motor
magnet coil and CR-35
Starting switch : START NO.1
chassis Defective start relay Replace
NO
Starting switch : START
Check operation Spec : 20~30V YES
YES Check voltage ⓐ
of start relay between CN-3
NO
CR-23 (2) and chassis
NO.4
POWER RY
NO
Starting switch : START wiring harness or
Starting switch : START poor contact
Check operation Spec : 20~30V between CN-3 (2) CS-74
of anti-restart -CR-5 (87) 1
NO relay CR-5 2
CN-95
NO.20
YES 2
Check voltage Defective anti- Replace 1 MASTER SW
between CR-5 restart relay FUSIBLE LINK

NO 2
(85, 86)
NO
ⓑ 1
CN-60
Spec : 20~30V
CR-1 BATTERY
YES
Check voltage Defective start relay Replace
ⓐ between CR-23 BATT RY
and chassis Disconnection in Repair or replace DO-3
NO
wiring harness or 2
Starting switch : START CN-51
poor contact ANTI-RESTART RY 20
1
Spec : 20~30V DIODE
between CN-3- MCU
CR-5
CR-5 CN-3 CR-23 START MOTOR
YES
Disconnection in Repair or replace 1 1
wiring harness or 2 2
Check voltage poor contact START RY
ⓑ between CR-5 between CN-51 CN-45
(86) and chassis ANTI-RESTART RY
(20)-CR-5 (85)
Starting switch : START NO Disconnection in Repair or replace
Spec : 20~30V wiring harness or
poor contact
between CS-2 (6)-
CR-5 (86)
3009SH6ES10
6-35
13. WHEN STARTING SWITCH ON DOES NOT OPERATE
·Before carrying out below procedure, check all the related connectors are properly inserted, master
switch ON and check open circuit of fusible link (CN-60).
START KEY SW
CN-5
CS-2
H0 I
35 1
Cause Remedy
0, I
36 2
59 3 4
H
YES 60
BR ACC
4 1
B
Disconnection in Repair or replace 5
2
3
wiring harness or (after clean) 6
poor contact
ST C
5
YES Check voltage

6
between DO-3 (1)-
between DO-3 CR-1 or defective
(1) and chassis battery relay CR-35
NO.1
Voltage : 20~30V
YES Check voltage NO wiring harness or (after clean)
between CS-2
poor contact
(2) and chassis NO.4
between CS-2 (2)- POWER RY
Voltage : 20~30V CN-5(60)- DO-3 (1)
Defective start Replace CS-74
NO
YES Check voltage switch 1
between CS-2 2
(1) and chassis YES CN-95
Disconnection in Replace NO.20 2
wiring harness or 1 MASTER SW
Voltage : 20~30V
poor contact FUSIBLE LINK
between CS-2 (1)-
Check voltage 2
CN-5 (36) 1
between CN-5
NO CN-60
Check voltage (36) and chassis YES
Disconnection in Charge or replace
and specific wiring harness or (after clean) CR-1 BATTERY
gravity of battery Voltage : 20~30V
Specific gravity : MIN 1.28 between CS-74 between CS-74 (1)
Voltage : MIN 24V NO -CN-5 (36)
(1) and chassis BATT RY
Voltage : 20~30V ⓐ DO-3
NO CN-51
2
1
ANTI-RESTART RY 20
DIODE
MCU
Battery capacity Charge or replace
NO too low (after clean) CR-5 CN-3 CR-23 START MOTOR
YES 1 1
Defective master Replace 2 2
Check voltage
ⓐ switch START RY
between CS-74
CN-45
(2)- chassis ANTI-RESTART RY
NO
Voltage : 20~30V wiring harness or (after clean)
poor contact
between CS-74 (2)
-CR-1
3009SH6ES11
6-36
14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse
No. 6, 11 and 17 is not blown out.
·After checking, insert the disconnected connectors again immediately unless otherwise specified. CN-21
3 1
Cause Remedy 2
5 3 CN-5
NO
Defective wiper Replace 4 4
cut switch 5
NO 6 M 2 6
Check operation wiring harness or (after clean)
wiper cut switch WIPER MOTOR FUSE
poor contact 18
between CN-141 NO.6
Front sliding door (11)- CS-53 CN-141 19
open-close
Check valtage
FEED BACK 1
between CN-141 YES
YES (11) and chassis Defective switch Replace MOTOR DRIVE SIG 2 CN-17
panel
NO Check voltage
MOTOR DRIVE- 3 1
Front sliding door-close between CN-116 MOTOR DRIVE+ 4 2
Voltage : 4~5V (10) and chassis GND 5 3
Check operation 1)Recheck fuse Replace FUSE
NO VCC 6 4 24
Starting switch : ON No.11
YES of switch panel Vottage : 20~30V CONTINUE 24V 7 5 NO.17
LED ON. 2)Disconnection in Repair or replace CN-22
wiring harness or (after clean) WASHER P/P 8 6
Starting switch : ON ⓐ 2 M
Push wiper switch button YES
poor contact WASHER SIG. 9 7
between INT. SIG 10 8 1
CN-116(6)-Fuse WIPER CUT SW 11 WASHER PUMP
between N.C 12
CN-116 (13)-Chassis FEED BACK 13
Check voltage between NO
Defective switch Replace WIPER MOTOR CONTROLLER
CN-116 (4) and chassis panel
Intermittent
NO CS-53
1) Recheck fuse Replace
Check voltage CN-116 No.6
ⓐ
(5) and chassis 2) Disconnection Repair or replace
Washing Check operation in wiring harness (after clean)
of wiper motor or poor contact
Check voltage CN-116 and controller between WIPER CUT SW
(3) and chassis check voltage CN-141(7)-Fuse,
YES CN-141 (7) and
Sarting switch : ON CN-21(4)-Fuse CN-116
Voltage : 0~1V
chassis, CN-21 HEAD LIGHT OUT 1
(4) and chassis NO
1) Recheck fuse Replace WORK LIGHT OUT 2
Starting switch : OFF No.17 INT. SIG 3
Voltage : 20~30V Check voltage WIPER MOTOR DRIVE 4
2) Disconnection Repair or replace
CN-141 (6) and WASHER SIG 5
YES chassis CN-141(6)-Fuse (after clean)
PRE-HEAT 6
CABIN LIGHT OUT 7
Starting switch : ON ⓑ
Check continuity YES TRAVEL ALARM 8
Voltage : 20~30V
NO NC 9 FUSE
between Disconnection in Repair or replace POWER 24V 10 57
CN-141 (2)-CN-116 (4), wiring harness or (after clean) GND 11 NO.11
CN-141 (9)-CN-116 (5), poor contact NC 12
CN-141 (10)-CN-116 (3),
ⓑ NO SWITCH PANEL
CN-141 (5)-Chassis , Check wiper Defective wiper Replace
CN-141 (1)-CN-21 (5), motor resistance motor
CN-141 (3)-CN-21 (6),
YES between CN-21
CN-141 (4)-CN-21 (2), (2)-CN-21 (6) Defective wiper Replace
CN-141 (13)-CN-21 (3) YES motor controller
Resistance : 3~4Ω
21096ES14
6-37
15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
CN-5
Cause Remedy FUSE
YES NO.18
Check voltage Defective bulb Replace
YES between CL-4 CN-116
(1) and chassis, HEAD LIGHT OUT 1
CL-3(1) and WORK LIGHT OUT 2
chassis Disconnection in Repair or replace INT. SIG 3
NO CR-13
Voltage : 20~30V wiring harness or (after clean) WIPER MOTOR DRIVE 4
30 30 86
poor contact WASHER SIG 5
Check voltage between CR-13 PRE-HEAT 6 86
YES
between CR-13 (87)-CL-4 (1) or CABIN LIGHT OUT 7 87
(87) and chassis CR-13 (87)-CL-3 TRAVEL ALARM 8 49 85
87a 87 85
(1) NC 9 87a
Starting switch : ON POWER 24V 10 HEAD LAMP RY
Head lamp switch : ON GND 11
Voltage : 20~30V YES NC 12
Defective switch Replace CL-4
panel SWITCH PANEL
Check voltage Check voltage 2
between CR-13 between CN-116 1
(30) and chassis, NO
(1) and chassis
CR-13 (86) and Repair or replace HEAD LAMP
Disconnection in
chassis Starting switch : ON NO (after clean)
Head lamp switch : ON wiring harness or
Voltage : 20~30V Voltage : 20~30V poor contact CL-3
between CN-116
(1)-CR-13 (87) 2
1
Disconnection in Repair or replace HEAD LAMP

poor contact
between CR-13
(30) and chassis
or CR-13 (86) -
chassis
Recheck fuse Replace

No. 18
3009SH6ES12
6-38
16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
Cause Remedy
YES
Defective bulb Replace
YES
Check voltage
between CL-5 (1)
and chassis CN-5
FUSE
NO wiring harness or (after clean) NO.15
poor contact
CN-116
between CR-4
YES Check voltage HEAD LIGHT OUT 1
between CR-4 (87)-CL-5 (2) WORK LIGHT OUT 2
(87) and chassis INT. SIG 3 CR-4
WIPER MOTOR DRIVE 4
Starting switch : ON 30 30 86
WASHER SIG 5
Work lamp switch : ON PRE-HEAT 6 86
Defective switch Replace CABIN LIGHT OUT 7 87
panel TRAVEL ALARM 8 50 85

87a 87 85
Check voltage Check voltage NC 9 87a
between CR-4 between CN-116 POWER 24V 10 WORK LAMP RY
(30) and chassis, NO GND 11
(2) and chassis
CR-4(86) chassis NC 12 CL-5
CN-12
Starting switch : ON Starting switch : ON Disconnection in Repair or replace SWITCH PANEL
Work lamp switch : ON NO 2 1
Voltage : 20~30V poor contact 1 2
between CR-4
(87)-CN-116 (2) WORK LAMP
1
NO
poor contact CL-6
between CR-4
(30) and chassis
or CR-4 (86) and
chassis

No.15
21096ES16
6-39
GROUP 3 ELECTRICAL SYSTEM (CLUSTER TYPE 2)
1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT
APPEAR
short of fuse No.8.
Cause Remedy
YES
YES Check voltage
between CN-56
(1) and chassis Disconnection in Repair or
NO
wiring harness or replace
Check voltage
between CN-5(5) poor contact (after clean)
and chassis between CN-5(5)-
CN-56(1)
Voltage : 20~32V
NO Disconnection in Repair or
wiring harness or replace
poor contact (after clean)
between CN-5(5)-
and fuse No.8
CLUSTER
FUSE
POWER IG(24V) 1 5
NO.8
GND 2 4
RX
TX
CN-56 CN-5
Check voltage
YES 20 ~ 32V
NO 0V
3009SH6ES20
6-40
2. COMMUNICATION ERROR FLASHES ON THE CLUSTER
Cause Remedy
YES
Defective controller Replace
YES Check voltage

between CN-56
(3,4) and chassis
between CN-5 between CN-56
(1,2)and chassis (3,4) CN-5(1,2)
KEY ON
NO
poor contact
between CN-5
(1,2)-CN-50
(29,30)
Check voltage
YES *4V *12V
NO 0V 0V
CLUSTER MCU
POWER IG(24V)
GND 2 4
*12V
RX 3 2 29
*4V
TX 4 1 30
CN-56 CN-5 CN-50
3009SH6ES21
6-41
3. BATTERY CHARGING WARNING LAMP LIGHTS UP(Starting switch : ON)
Cause Remedy
YES
Defective controller Replace
YES Check voltage
between CN-51
(9) and chassis Disconnection in Repair or replace
NO
YES poor contact
between CN-3(3)
and chassis between CN-51(9)
-CN-3(3)

Check voltage NO wiring harness or (after clean)
between CN-74(2) poor contact
and chassis between CN-3(3)-
CN-74(1)
Voltage : 20~32V
Engine : Running
NO
Defective alternator Replace
Check voltage
YES 20 ~ 32V
NO 0V
ALTERNATOR
B+
MCU
G
1 P
27 3 2 L
3 ~
U
3 FI
4 NC
CN-74
CN-52 CN-3
3009S6ES01
6-42
4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Coolant overheat Check engine
(110。C±2。C) cooling system
YES Resistance
between CD-8
(1,2) is in range
of 120~150Ω?
Disconnect : CD-8 Replace
NO Defective temp
Does display go
sensor
off when
disconnect
CD-8?
Starting switch : ON YES
Engine : Start Shot circuit in Repair or replace
Resistance
between CN-51 wiring harness (after clean)
NO (31,33) is
0~1Ω? Defective MCU Replace
NO
Disconnect : CD-51
KEY OFF
12th step
Check Table
Range 1st step 2nd~10th step 11th~12th step
Temperature ~29。C 30~105。C 105。C ~
1 st step
MCU
WATER TEMP SENDER
31 5 1 C
33 6 2
CN-3 CD-8
CN-51
3009SH6ES23
6-43
5. WHEN AIR CLEANER WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Clogged air filter or Check filter or
defective switch replace switch
Does display go off
when disconnect YES
CD-10? Short circuit in Repair or replace
Starting switch : ON Check resistance wiring harness (after clean)
Engine : Start between CN-51
NO
(16) and chassis
NO
Disconnect CN-51
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
MCU AIR CLEANER SWITCH
Pa
16
CD-10
CN-51
3009SH6ES24
6-44
6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Does display go
off when Engine oil leakage Check engine oil
disconnect
CD-18? of defective switch level or replace
Starting switch : ON switch
Does the gauge
light up and
down at lamp
check? YES Defective controller
Starting switch : ON Check resistance Replace
Engine : Start between
NO CN-51(4) and
chassis Disconnection in Repair or replace
NO
Disconnect : CN-51
poor contact
between CN-51(4)
-CD-18
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
MCU ENGINE OIL PRESSURE SWITCH
4 1 Pa
CN-51 CN-2 CD-18
3009SH6ES25
6-45
7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
High temperature Check hydraulic
Resistance oil temperature
YES between CD-1 (100˚C±2˚C)
(1,2) is in range
of 130~150Ω?
Starting switch : ON Defective temp Replace
Does display go Disconnect CD-1 NO
sensor
off when
disconnect CD-1? YES
Short circuit Check and repair
Engine : Start
Resistance
between CN-51
NO (31,34) is 0~1Ω?

Disconnect CN-51
MCU HYDRAULIC OIL

TEMPERATURE SENDER
31 1 C
34 2
CD-1
CN-51
3009SH6ES26
6-46
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
Cause Remedy
YES
Is resistance poor contact
YES between
between
CN-51(31) and
(33) over 2kΩ? CN-51-CD-8
Starting switch : ON YES
Does the gauge Check resistance
light up and down between CN-2(5)
NO
at lamp check? and (6)
NO Defective temp Replace
Starting switch : ON Spec : 120Ω
See table sensor
NO
12th step Check Table

Range 1st step 2nd~10th step 11th~12th step
Temperature ~29。C 30~105。C 105。C ~
1 st step
MCU
WATER TEMP SENDER
31 5 1 C
33 6 2
CN-3 CD-8
CN-51
3009SH6ES23
6-47
9. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
Cause Remedy
YES
Disconnection in Check and repair
wiring harness
Is resistance
YES between CN-51
(24) and (31)
over 1kΩ? YES
Disconnect CN-51
Check resistance
Does the gauge between CD-2(1)
light up and NO and (2)
down at lamp Defective fuel Replace
Disconnect CD-2 NO
check? sensor
See Table

NO
2nd~10th step
Check Table
1 st step 11th~12th
step Range
Item 1st step 2nd~10th step 11th~12th step
Unit Resistance(Ω) 700~601 600~101 ~100

Tolerance(%) ±5 ±5 ±5
MCU
FUEL LEVEL SENDER
24 2
31 1
CD-2
CN-51
3009SH6ES27
6-48
10. WHEN SAFETY SOLENOID DOES NOT OPERATE
Cause Remedy
YES
Hydraulic system Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
Safety lever : ON-OFF NO
YES
Defective switch Replace
YES Check voltage
between CS-4(C)
Check voltage and chassis
between Disconnection in Repair or replace
CN-68(1) - (2) Start switch : ON NO
YES Check voltage Voltage : 20~30V
Starting switch : ON between CN-4(16) Disconnect CN-4 poor contact
Voltage : 20~30V and chassis between
Safety state
Starting switch : ON CS-4(C)-CN-68(1)
Voltage : 20~30V
Disconnect CN-4
Check voltage Disconnect in Repair or replace
NO
between CN-68(2) wiring harness or (after clean)
NO
with chassis poor contact
between
Safety lever : OFF
Starting switch : ON CN-4(16)-CN-68(1)
Voltage : 20~30V
Disconnection in Replace
NO
fuse No. 23
FUSE
NO.23
SAFETY SWITCH
B C A 14 SAFETY SOLENOID
B 15 2
A C 16 1
CS-4 CN-68
CN-4
21096ES10
6-49
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE
short of fuse No.28 .
Cause Remedy
YES
Defective hydraulic Check hydraulic
system system
YES Check voltage YES Check operation
between CN-50 YES
of solenoid Defective MCU Replace
(13) and chassis
Check resistance
Check if travel Starting switch : ON Starting switch : ON between CN-70
Voltage : 20~30V : OFF NO Defective solenoid
speed lamps( , (1) and (2)
Disconnect CN-50 : ON
) change when Replace
pressing the travel
SPEC : 15~25Ω
speed switch on Disconnect CN-70
the cluster Defective cluster
YES
Starting switch : ON Replace
Check controller
Y R G
NO Defective MCU
Replace
NO
FUSE
MCU NO.28
TRAVEL SOLENOID
13 1
CN-70
CN-50
3009SH6ES28
6-50
12. WHEN ENGINE DOES NOT START ( lights up condition)
short of fuse No. 1, 4, 20.
Cause Remedy
YES START KEY SW
Delective battery Replace CN-5
CS-2
H0 I
35 1
0, I
36 2
59 3 4
H
60
BR ACC
4 1
B
2
5 3
6
Check operation YES
ST C
5
Check voltage Defective magnet Replace 6
start motor
YES between starter of start motor
magnet coil and CR-35
Starting switch : START NO.1
chassis Defective start relay Replace
NO
Check operation Spec : 20~30V YES
YES Check voltage ⓐ
of start relay between CN-3
NO
CR-23 (2) and chassis
NO.4
POWER RY
NO
Starting switch : START wiring harness or
Starting switch : START poor contact
Check operation Spec : 20~30V between CN-3 (2) CS-74
of anti-restart -CR-5 (87) 1
NO relay CR-5 2
CN-95
NO.20
YES 2
Check voltage Defective anti- Replace 1 MASTER SW
between CR-5 restart relay FUSIBLE LINK

NO 2
(85, 86)
NO
ⓑ 1
CN-60
Spec : 20~30V
CR-1 BATTERY
YES
Check voltage Defective start relay Replace
ⓐ between CR-23 BATT RY
and chassis Disconnection in Repair or replace DO-3
NO
wiring harness or 2
Starting switch : START CN-50
poor contact ANTI-RESTART RY 11
1
Spec : 20~30V DIODE
between CN-3- MCU
CR-5
CR-5 CN-3 CR-23 START MOTOR
YES
Disconnection in Repair or replace 1 1
wiring harness or 2 2
Check voltage poor contact START RY
ⓑ between CR-5 between CN-50 CN-45
(86) and chassis ANTI-RESTART RY
(11)-CR-5 (85)
Starting switch : START NO Disconnection in Repair or replace
Spec : 20~30V wiring harness or
poor contact
between CS-2 (6)-
CR-5 (86)
3009SH6ES29
6-51
13. WHEN STARTING SWITCH ON DOES NOT OPERATE
·Before carrying out below procedure, check all the related connectors are properly inserted, master
switch ON and check open circuit of fusible link (CN-60).
START KEY SW
CN-5
CS-2
H0 I
35 1
Cause Remedy
0, I
36 2
59 3 4
H
YES 60
BR ACC
4 1
B
2
3
wiring harness or (after clean) 6
poor contact
ST C
5
YES Check voltage

6
between DO-3 (1)-
between DO-3 CR-1 or defective
(1) and chassis battery relay CR-35
NO.1
Voltage : 20~30V
YES Check voltage NO wiring harness or (after clean)
between CS-2
poor contact
(2) and chassis NO.4
between CS-2 (2)- POWER RY
Voltage : 20~30V CN-5(60)- DO-3 (1)
Defective start Replace CS-74
NO
YES Check voltage switch 1
between CS-2 2
(1) and chassis YES CN-95
Disconnection in Replace NO.20 2
wiring harness or 1 MASTER SW
Voltage : 20~30V
poor contact FUSIBLE LINK
between CS-2 (1)-
Check voltage 2
CN-5 (36) 1
between CN-5
NO CN-60
Check voltage (36) and chassis YES
and specific wiring harness or (after clean) CR-1 BATTERY
gravity of battery Voltage : 20~30V
Specific gravity : MIN 1.28 between CS-74 between CS-74 (1)
Voltage : MIN 24V NO -CN-5 (36)
(1) and chassis BATT RY
Voltage : 20~30V ⓐ DO-3
NO CN-50
2
1
ANTI-RESTART RY 11
DIODE
MCU
Battery capacity too Charge or replace
NO low (after clean) CR-5 CN-3 CR-23 START MOTOR
YES 1 1
Defective master Replace 2 2
Check voltage
ⓐ switch START RY
between CS-74
CN-45
(2)- chassis ANTI-RESTART RY
NO
poor contact
between CS-74 (2)
-CR-1
3009SH6ES30
6-52
14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse
No. 6, 11 and 17 is not blown out.
·After checking, insert the disconnected connectors again immediately unless otherwise specified. CN-21
3 1
Cause Remedy 2
5 3 CN-5
NO
Defective wiper Replace 4 4
cut switch 5
NO 6 M 2 6
Check operation wiring harness or (after clean)
wiper cut switch WIPER MOTOR FUSE
poor contact 18
between CN-141 NO.6
Front sliding door (11)- CS-53 CN-141 19
open-close
Check valtage
FEED BACK 1
between CN-141 YES
YES (11) and chassis Defective switch Replace MOTOR DRIVE SIG 2 CN-17
panel
NO Check voltage
MOTOR DRIVE- 3 1
Front sliding door-close between CN-116 MOTOR DRIVE+ 4 2
Voltage : 4~5V (10) and chassis GND 5 3
Check operation 1)Recheck fuse Replace FUSE
NO VCC 6 4 24
Starting switch : ON No.11
YES of switch panel Vottage : 20~30V CONTINUE 24V 7 5 NO.17
LED ON. 2)Disconnection in Repair or replace CN-22
wiring harness or (after clean) WASHER P/P 8 6
Starting switch : ON ⓐ 2 M
Push wiper switch button YES
poor contact WASHER SIG. 9 7
between INT. SIG 10 8 1
CN-116(6)-Fuse WIPER CUT SW 11 WASHER PUMP
between N.C 12
CN-116 (13)-Chassis FEED BACK 13
Check voltage between NO
Defective switch Replace WIPER MOTOR CONTROLLER
CN-116 (4) and chassis panel
Intermittent
NO CS-53
1) Recheck fuse Replace
Check voltage CN-116 No.6
ⓐ
(5) and chassis 2) Disconnection Repair or replace
Washing Check operation in wiring harness (after clean)
of wiper motor or poor contact
Check voltage CN-116 and controller between WIPER CUT SW
(3) and chassis check voltage CN-141(7)-Fuse,
YES CN-141 (7) and
Sarting switch : ON CN-21(4)-Fuse CN-116
Voltage : 0~1V
chassis, CN-21 HEAD LIGHT OUT 1
(4) and chassis NO
1) Recheck fuse Replace WORK LIGHT OUT 2
Starting switch : OFF No.17 INT. SIG 3
Voltage : 20~30V Check voltage WIPER MOTOR DRIVE 4
2) Disconnection Repair or replace
CN-141 (6) and WASHER SIG 5
YES chassis CN-141(6)-Fuse (after clean)
PRE-HEAT 6
CABIN LIGHT OUT 7
Starting switch : ON ⓑ
Check continuity YES TRAVEL ALARM 8
Voltage : 20~30V
NO NC 9 FUSE
between Disconnection in Repair or replace POWER 24V 10 57
CN-141 (2)-CN-116 (4), wiring harness or (after clean) GND 11 NO.11
CN-141 (9)-CN-116 (5), poor contact NC 12
CN-141 (10)-CN-116 (3),
ⓑ NO SWITCH PANEL
CN-141 (5)-Chassis , Check wiper Defective wiper Replace
CN-141 (1)-CN-21 (5), motor resistance motor
CN-141 (3)-CN-21 (6),
YES between CN-21
CN-141 (4)-CN-21 (2), (2)-CN-21 (6) Defective wiper Replace
CN-141 (13)-CN-21 (3) YES motor controller
Resistance : 3~4Ω
21096ES14
6-53
15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
CN-5
Cause Remedy FUSE
YES NO.18
Check voltage Defective bulb Replace
YES between CL-4 CN-116
(1) and chassis, HEAD LIGHT OUT 1
CL-3(1) and WORK LIGHT OUT 2
chassis Disconnection in Repair or replace INT. SIG 3
NO CR-13
Voltage : 20~30V wiring harness or (after clean) WIPER MOTOR DRIVE 4
30 30 86
poor contact WASHER SIG 5
Check voltage between CR-13 PRE-HEAT 6 86
YES
between CR-13 (87)-CL-4 (1) or CABIN LIGHT OUT 7 87
(87) and chassis CR-13 (87)-CL-3 TRAVEL ALARM 8 49 85
87a 87 85
(1) NC 9 87a
Starting switch : ON POWER 24V 10 HEAD LAMP RY
Head lamp switch : ON GND 11
Voltage : 20~30V YES NC 12
Defective switch Replace CL-4
panel SWITCH PANEL
Check voltage Check voltage 2
between CR-13 between CN-116 1
(30) and chassis, NO
(1) and chassis
CR-13 (86) and Repair or replace HEAD LAMP
Disconnection in
chassis Starting switch : ON NO (after clean)
Head lamp switch : ON wiring harness or
Voltage : 20~30V Voltage : 20~30V poor contact CL-3
between CN-116
(1)-CR-13 (87) 2
1
Disconnection in Repair or replace HEAD LAMP

poor contact
between CR-13
(30) and chassis
or CR-13 (86) -
chassis

No. 18
3009SH6ES12
6-54
16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
Cause Remedy
YES
Defective bulb Replace
YES
Check voltage
between CL-5 (1)
and chassis CN-5
FUSE
NO wiring harness or (after clean) NO.15
poor contact
CN-116
between CR-4
YES Check voltage HEAD LIGHT OUT 1
between CR-4 (87)-CL-5 (2) WORK LIGHT OUT 2
(87) and chassis INT. SIG 3 CR-4
WIPER MOTOR DRIVE 4
Starting switch : ON 30 30 86
WASHER SIG 5
Work lamp switch : ON PRE-HEAT 6 86
Defective switch Replace CABIN LIGHT OUT 7 87
panel TRAVEL ALARM 8 50 85

87a 87 85
Check voltage Check voltage NC 9 87a
between CR-4 between CN-116 POWER 24V 10 WORK LAMP RY
(30) and chassis, NO GND 11
(2) and chassis
CR-4(86) chassis NC 12 CL-5
CN-12
Starting switch : ON Starting switch : ON Disconnection in Repair or replace SWITCH PANEL
Work lamp switch : ON NO 2 1
Voltage : 20~30V poor contact 1 2
between CR-4
(87)-CN-116 (2) WORK LAMP
1
NO
poor contact CL-6
between CR-4
(30) and chassis
or CR-4 (86) and
chassis

No.15
21096ES16
6-55
GROUP 4 MECHATRONICS SYSTEM (CLUSTER TYPE 1)
1. ALL ACTUATORS SPEED ARE SLOW

※ Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
※ Spec : P-mode 2100 ± 50 rpm S -mode 2000 ± 50 rpm E-mode 1900± 50 rpm
※ Before carrying out below procedure, check all the related connectors are properly inserted and
fault code on the cluster.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective
YES Check pressure hydraulic system
at EPPR valve
NO Check electric Defective Replace
current at EPPR SPEC : 5~20 kgf/cm2
NO
EPPR valve
valve See TEST 3
SPEC : 100~700 mA
See TEST 2
Check if HCESPN NO
140 active fault
display on the LCD YES
Short circuit or Check & repair
poor connection wire harness or
Check resistance
YES at EPPR valve -CN-75 -CN-75
SPEC : 15~25Ω(20。C) Defective EPPR Replace

See TEST 1 NO
valve
Wiring diagram
MCU
FUSE
8
NO.10
9
PUMP EPPR VALVE
9 2
19 10 1
CN-52 CN-2 CN-75
3309S6MS01
6-56
2) TEST PROCEDURE SPEC : 15~25Ω(20˚C)
(1) Test 1 : Check resistance at connector
CN-75
CN-75.
Multimeter
① Starting key OFF.
② Disconnect connector CN-75 from EPPR
valve at main hydraulic pump.
③ Check resistance between 2 lines as
figure. EPPR valve
29096MS01
(2) Test 2 : Check electric current at EPPR SPEC : 160~460 mA (S mode)

valve.
① Install multimeter as figure.
② Start engine. CN-75
Multimeter
③ Set the accel dial at "10" (MAX)
④ Set S-mode and cancel auto decel
mode.
⑤ If tachometer show approx 2000±50 rpm,
EPPR valve
check electric current.
Main pump
21095MS21
(3) Test 3 : Check pressure at EPPR valve. SPEC : 4~20 kgf/cm2 (60~280 psi)
Pressure adjusting
gauge as figure. Supply line,
screw locknut
·Gauge capacity : 0 to 50 kgf/cm2 pilot pressure CN-75
(0 to 710 psi)
② Start engine.
③ Set the accel dial at "10" (Max).
④ Set S-mode and cancel auto decel EPPR valve
mode.
check pressure.
29095MS10
6-57
2. ENGINE STALL
※ Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Not enough Check engine
engine power fault
YES Check pressure Contact cummins
at EPPR valve
SPEC:5~20 kgf/cm2 Defective EPPR Replace

See TEST 5 NO
Check electric valve
current at EPPR
valve
YES
Short circuit or Check and repair
SPEC : 100~700 mA poor connection wire harness
See TEST 4
Check resistance between
between CN-52 - CN-75
NO at EPPR valve
SPEC : 15~25Ω(20˚C)
See TEST 1
NO
Defective EPPR Replace
valve
Wiring diagram
MCU
FUSE
8
NO.10
9
PUMP EPPR VALVE
9 2
19 10 1
CN-52 CN-2 CN-75
3309S6MS01
6-58
2) TEST PROCEDURE SPEC : 100~700 mA
(1) Test 4 : Check electric current at EPPR Adapter(P/no.:21Q6-50410)
valve at S-mode
CN-75
① Install multimeter as figure. Multimeter
② Start engine.
③ Set the accel dial at "10" (max)
④ Set S-mode with 2000±50 rpm.
⑤ Check electric current. EPPR valve
Main pump
21095MS21
(2) Test 5 : Check pressure at EPPR valve at SPEC : 4~20 kgf/cm2 (60~280 psi)
S-mode
① Connect pressure gauge at EPPR valve. Pressure adjusting
screw locknut
② Start engine. Supply line,
④ Set S-mode with 2000±50 rpm.
⑤ Operate bucket lever completely push or
pull. EPPR valve
⑥ Hold arm lever at the end of stroke.
⑦ Check pressure at relief position.
29095MS10
6-59
3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
Cause Remedy
YES
No power supply to Check fuse No.3
See if all lamps the MCU
YES off in the MCU
case YES
Y R G MCU failure Replace
Y R G
See if HCESPN
840 active fault NO
display on the LCD
NO Y R G
ⓐ
NO
OK
Check connection Cluster failure Replace
between CN-51
ⓐ (33) - CN-56(4) or
CN-51(23) -
CN-56(8) No connection Check and repair
NO
KEY OFF
Wiring diagram
CLUSTER MCU
BATT.24V
SIG 3
GND
TX 4 1 33
IG 24V 8 2 23
SIG 2
CN-56 CN-5 1
CAMERA SIG
RX CN-51
FUSE
NO.3
3009SH6MS02
6-60
4. MALFUNCTION OF ACCEL DIAL
Cause Remedy
YES
YES
Open circuit or Replace or repair
poor connection
between CN-7
Check voltage YES Check voltage
between (15)-CN-52 (23)
between
CN-52(23)-GND CN-7(15)-GND YES
Check resistance Defective accel Replace
Spec : actuator operating
Spec : actuator operating between dial
1~5V
1~5V
NO CN-142(B)-
See TEST 6 CN-7(15) Open circuit or Replace or repair
Check voltage NO
Spec : 0Ω poor connection
NO
CN142(A)-(C) (B)-CN-7 (15)
Spec : 5V YES CN-52
poor connection
between CN-142 23
Check voltage (A)-CN-7 (14) or
between CN-142 (C )-
NO CN-7(14)-(16)
CN-7 (16)
MCU
Spec : 5V
NO poor connection ACCEL DIAL
between CN-7 + A 14 5
(16)-CN-51 (5) or
S B 15 6
CN-7 (14 )-
CN-51 (6) - C 16
CN-142
CN-7 CN-51
3009SH6MS03
6-61
2) TEST PROCEDURE SPEC : Actuator operating : 1~5 V
(1) Test 6 : Check voltage at CN-52(23) and
ground.
① Prepare 1 piece of thin sharp pin, steel or
MCU
copper.
PIN
② Insert prepared pin to rear side of CN-51 CN-52
connectors : One pin to (23) of CN-52.
③ Starting key ON.
④ Check voltage as figure.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
23
30
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
3009SH6MS04
6-62
5. AUTO DECEL SYSTEM DOES NOT WORK
· Fault code : HCESPN 105, FMI 0~4 (work pressure sensor)
HCESPN 108, FMI 0~4 (travel oil pressure sensor)
Cause Remedy
YES
YES
Defective travel Replace
Check voltage
NO pressure switch
between CD-6(A)
and (C)
Short circuit or poor Replace or repair
NO
Check voltage SPEC : connection
between CN-52 Key ON : 24±2V between CN-51(3)-
(38)-GND and CD-6(A) and / or
CN-52(37)-GND CN-51(13)-CD-
6(C) (fault code 108
SPEC :
Actuator operating : 1~5V
displayed)
See TEST 7, 8 YES
Defective work Replace
Check voltage
pressure sensor
between CD-7(A)
NO and (C)
NO
SPEC : connection
Key ON : 24±2V between CN-51(3)-
CD-7(A) and / or
CN-51(13)-CD-
7(C) (fault code 105
displayed)
Wiring diagram
CN-51
CD-6
3 A SUPPLY
B SIG
13 C RETURN
TRAVEL PRESSURE SENSOR
MCU
38 CD-7
A SUPPLY
37 B SIG
C RETURN
CN-52 WORK PRESSURE SENSOR
3009SH6MS05
6-63
ground.
① Prepare 1 piece of thin sharp pin, steel or MCU
PIN
copper.
CN-51 CN-52
② Insert prepared pin to rear side of
(2) Test 8 : Check voltage at CN-52(37)and
ground.
10 9 8 7 6 5 4 3 2 1
20 11 CN-52
copper 30
38
21
Female
② Insert prepared pin to rear side of 40 39 38 37 36 34 33 32 31

GROUND
Multimeter
10 9 8 7 6 5 4 3 2 1
20 11 CN-52
30
37
21 Female
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
3009SH6MS06
6-64
6. MALFUNCTION OF PUMP 1 PRESSURE SENSOR
· Fault code : HCESPN 120, FMI 0~4
Cause Remedy
YES
YES
Short circuit or Replace or repair
poor connection
YES Check voltage between CN-52-
between
CN-2(6)-GND (29)-CN-2(6)
Check voltage SPEC : Detective P1 Replace or repair
between CN-52 Actuator operating: 1~5V NO
Check voltage pressure sensor
(29) - GND YES between short circuit or poor
SPEC : CD-42(A)-(C) connection
Actuator operating: 1~5V between CN-2(6)-
See TEST 9 SPEC :
Key ON : 24±2V CD-42(B)
Check voltage Short circuit or Replace or repair

NO
between poor connection
NO CN-2(13)-(15) between CD-42(A)-
CN-2(13) or
SPEC :
Key ON : 24±2V
CD-42(C)-
CN-2(15)

NO poor connection
between CN-2(13)-
CN-51(3) or CN-2
(15) - CN-51(13)
Wiring diagram
CN-51
CD-42
3 13 A SUPPLY
6 B SIG
13 15 C RETURN
PUMP 1 PRESSURE SENSOR
CN-2
MCU
29
CN-52
3009SH6MS07
6-65
ground.
copper. PIN

CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
29
30
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
3009SH6MS08
6-66
Cause Remedy
YES
YES
poor connection
between
CN-2(7)-GND (30)-CN-2(7)
(30) - GND YES between short circuit or
SPEC : CD-43(A)-(C) poor connection
See TEST 10 SPEC :
Key ON : 24±2V CD-43(B)

NO
NO CN-2(13)-(15) between D-43(A)-
CN-2(13) or
SPEC :
Key ON : 24±2V
CD-43(C)-
CN-2(15)

NO poor connection
between
CN-2(13)-
CN-51(3) or CN-2
(15)-CN-51(13)
Wiring diagram
CN-51
CD-43
3 13 A SUPPLY
7 B SIG
13 15 C RETURN
CN-2
MCU
30
CN-52
3009SH6MS09
6-67
ground.
copper. PIN

CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30
30
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
3009SH6MS10
6-68
Cause Remedy
YES
YES
poor connection
between
CN-2(4)-GND (32)-CN-2(4)
See TEST 11 SPEC :
Key ON : 24±2V CD-44(B)

NO
NO CN-2(13)-(15) between D-44(A)-
CN-2(13) or
SPEC :
Key ON : 24±2V
CD-44(C)-
CN-2(15)

NO poor connection
between
CN-2(13)-
CN-51(4) or CN-2
(15) - CN-51(5)
Wiring diagram
CN-51
CD-44
3 13 A SUPPLY
4 B SIG
13 15 C RETURN
CN-2
MCU
32
CN-52
3009SH6MS11
6-69
ground.
copper. PIN

CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30
32
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
3009SH6MS12
6-70
9. MALFUNCTION OF SWING PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

between CN-52 Detective swing Replace or repair
(36) - GND pressure sensor
SPEC : short circuit or
Actuator operating: 1~5V Check voltage poor connection
See TEST 14 between CD-24 between CN-52
NO (A)-(C) (36)-CD-24 (B)
SPEC :
Key ON : 24±2V
NO
poor connection
between CD-24
(A)-CN-51(3) or
CD-24(C)- CN-51
(13)
Wiring diagram
CN-51
CD-24
3 A SUPPLY
B SIG
13 C RETURN
SWING PRESSURE SENSOR
MCU
36
CN-52
3009SH6MS13
6-71
ground.
MCU
copper. PIN

CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30
36
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
3009SH6MS14
6-72
10. MALFUNCTION OF BOOM UP PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

between CN-52 Detective boom up Replace or repair
(35) - GND pressure sensor
SPEC : short circuit or
Actuator operating: 1~5V Check voltage poor connection
See TEST 16 between CD-32 between CN-52
NO (A)-(C) (35)-CD-32 (B)
SPEC :
Key ON : 24±2V
NO
poor connection
between CD-32
(A)-CN-51(3) or
CD-32(C)- CN-51
(13)
Wiring diagram
CN-51
CD-32
3 A SUPPLY
B SIG
13 C RETURN
BOOM UP PRESSURE SENSOR
MCU
35
CN-52
3009SH6MS15
6-73
ground.
copper. PIN

CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30
35
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
3009SH6MS16
6-74
11. MALFUNCTION OF POWER MAX
· Fault code : HCESPN 166, FMI 4 or 6
Cause Remedy
YES
Short circuit or poor Repair or replace
connection between
YES Check resistance CN-88(1)-CN-52 (2)
between CN-88
(1)-(2)
Defective power
NO
YES Check resistance SPEC: 15-35Ω max. solenoid valve Repair or replace
between CN-53 See TEST 18 Check hydraulic
(18)-GND
system
Is voltage between Short circuit or poor Repair or replace

NO
CN-88(2)-GND connection between
SPEC : Power max button pressed ON : 0Ω
normal? Power max button released OFF : ∞ Ω CN-51(18)-CS-29
SPEC
KEY ON : 24±1V
KEY OFF : 0V Short circuit or poor Repair or replace
See TEST 17 NO
connection between
CN-88(2)-
Fuse No. 25
Wiring diagram
MCU
CN-88
2 1
2
CN-52
POWER MAX SOLENOID
18 5
FUSE
6
NO.25
CN-51 CN-4
CS-29
1
2
POWER MAX SWITCH
3009SH6MS17
6-75
2) TEST PROCEDURE SPEC : Key ON : 24±1V
Key OFF : 0V
(1) Test 17:
17 Check voltage between connector
CN-88(2) - GND.
① Disconnect connector CN-88 from power
max solenoid valve. Power max switch
② Start key ON.
③ Check voltage as figure.
LH RCV-lever
CN-88
Power max
solenoid valve
2 1
1 2
GROUND
Multimeter
21096MS14A
(2) Test 18:

18 Check resistance of the solenoid SPEC : 15~35Ω
valve between CN-88(1)-(2).
Power max switch
② Disconnect connector CN-88 from power
max solenoid valve.
③ Check resistance as figure.
LH RCV-lever
CN-88
Power max 2 1
solenoid valve
1 2
Multimeter
21096MS14B
6-76
12. MALFUNCTION OF BOOM PRIORITY EPPR VALVE
Cause Remedy
YES
connection between
CN-52(17)-CN-133
Check resistance (1) or CN-52(7)-
between CN-133(2)
CN-133(1)-(2)
SPEC : 15~35V
KEY : ON
Defective EPPR Repair or replace
NO
valve
Wiring diagram
MCU
17
CN-133
7 2
BOOM PRIORITY
EPPR VALVE
CN-52
3009SH6MS18
6-77
13. MALFUNCTION OF ARM REGENERATION SOLENOID
Cause Remedy
YES
YES Check voltage

YES
between CN-52 Short circuit or Replace or repair
(1)-GND
poor connection
Check resistance between CN-52
SPEC :
KEY ON 24±2V between arm
Check voltage NO (1)-CN-135 (1)
See TEST 19 regen solenoid
between CN-135(2)
- GND SPEC : 15~35Ω Defective Replace
NO
SPEC : solenoid valve
KEY ON : 20~30V
Open circuit Replace or repair

NO
between CN-135
(2)-Fuse No. 25
Wiring diagram
MCU
CN-135
1 1
ARM REGENERATION SOLENOID
FUSE
NO.25
CN-52
3009SH6MS19
6-78
2) TEST PROCEDURE SPEC : Key ON : 24±2 V
ground.
copper. MCU
② Insert prepared pin to rear side of PIN
CN-51 CN-52 CN-53
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30 21
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
21096MS16A
6-79
■ MECHATRONICS SYSTEM (CLUSTER TYPE 2)
1. ALL ACTUATORS SPEED ARE SLOW

※ Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
※ Spec : P-mode 2100 ± 50 rpm S -mode 2000 ± 50 rpm E-mode 1900 ± 50 rpm
※ Before carrying out below procedure, check all the related connectors are properly inserted and
fault code on the cluster.
Cause Remedy
YES
Defective
YES Check pressure hydraulic system
at EPPR valve
NO Check electric Defective Replace
current at EPPR SPEC : 5~20 kgf/cm2
NO
EPPR valve
valve See TEST 3
SPEC : 100~700 mA
See TEST 2
Check if HCESPN NO
140 active fault
display on the LCD YES
Short circuit or Check & repair
poor connection wire harness or
Check resistance
YES at EPPR valve -CN-75 -CN-75
SPEC : 15~25Ω(20。C) Defective EPPR Replace

See TEST 1 NO
valve
Wiring diagram
MCU
FUSE
24
NO.9
36
28 PUMP EPPR VALVE
9 2
8 10 1
CN-50 CN-2 CN-75
3009SH6MS30
6-80
2) TEST PROCEDURE SPEC : 15~25Ω(20˚C)
(1) Test 1 : Check resistance at connector
CN-75
CN-75.
Multimeter
② Disconnect connector CN-75 from EPPR
valve at main hydraulic pump.
③ Check resistance between 2 lines as
figure. EPPR valve
29096MS01
(2) Test 2 : Check electric current at EPPR SPEC : 160~460 mA (S mode)

valve.
① Install multimeter as figure.
② Start engine. CN-75
Multimeter
③ Set the accel dial at "10" (MAX)
④ Set H-mode and cancel auto decel
mode.
EPPR valve
check electric current.
Main pump
21095MS21
(3) Test 3 : Check pressure at EPPR valve. SPEC : 4~20 kgf/cm2 (60~280 psi)
Pressure adjusting
gauge as figure. Supply line,
screw locknut
·Gauge capacity : 0 to 50 kgf/cm2 pilot pressure CN-75
(0 to 710 psi)
② Start engine.
③ Set the accel dial at "10" (Max).
④ Set H-mode and cancel auto decel EPPR valve
mode.
check pressure.
29095MS10
6-81
2. ENGINE STALL
Cause Remedy
YES
Not enough Check engine
engine power fault
YES Check pressure Contact cummins
at EPPR valve
SPEC:5~20 kgf/cm2 Defective EPPR Replace

See TEST 5 NO
Check electric valve
current at EPPR
valve
YES
Short circuit or Check and repair
SPEC : 100~700 mA poor connection wire harness
See TEST 4
Check resistance between
between CN-50 - CN-75
NO at EPPR valve
SPEC : 15~25Ω(20˚C)
See TEST 1
NO
Defective EPPR Replace
valve
Wiring diagram
MCU
FUSE
24
NO.9
36
28 PUMP EPPR VALVE
9 2
8 10 1
CN-50 CN-2 CN-75
3009SH6MS30
6-82
2) TEST PROCEDURE SPEC : 100~700 mA
(1) Test 4 : Check electric current at EPPR Adapter(P/no.:21Q6-50410)
valve at S-mode
CN-75
① Install multimeter as figure. Multimeter
② Start engine.
④ Set H-mode with 2000±50 rpm.
⑤ Check electric current. EPPR valve
Main pump
21095MS21
(2) Test 5 : Check pressure at EPPR valve at SPEC : 4~20 kgf/cm2 (60~280 psi)
S-mode
① Connect pressure gauge at EPPR valve. Pressure adjusting
screw locknut
② Start engine. Supply line,
④ Set H-mode with 2000±50 rpm.
⑤ Operate bucket lever completely push or
pull. EPPR valve
⑥ Hold arm lever at the end of stroke.
⑦ Check pressure at relief position.
29095MS10
6-83
3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
Cause Remedy
YES
No power supply to Check fuse No.3
See if all lamps the MCU
YES off in the MCU
case YES
Y R G MCU failure Replace
Y R G
See if Co : Er
current error NO
display on the LCD
NO Y R G
ⓐ
NO
OK
Check connection Cluster failure Replace
between CN-50
ⓐ (29) - CN-56(3) or
CN-50(30) -
CN-56(4) No connection Check and repair
NO
KEY OFF
Wiring diagram
MCU
POWER IG(24V)
GND
RX 3 2 29
TX 4 1 30
CLUSTER
CN-56 CN-5 7
CN-50
FUSE
NO.3
3009SH6MS31
6-84
4. MALFUNCTION OF ACCEL DIAL
Cause Remedy
YES
YES
poor connection
between CN-7
Check voltage YES Check voltage
between (15)-CN-51 (23)
between
CN-51(23)-GND CN-7(15)-GND YES
Check resistance Defective accel Replace
Spec : actuator operating
Spec : actuator operating between dial
1~5V
1~5V
NO CN-142(B)-
See TEST 6 CN-7(15) Open circuit or Replace or repair
Check voltage NO
Spec : 0Ω poor connection
NO
CN142(A)-(C) (B)-CN-7 (15)
Spec : 5V YES
poor connection
between CN-142
Check voltage (A)-CN-7 (14) or MCU
between CN-142 (C )-
NO CN-7(14)-(16) ACCEL DIAL 20
CN-7 (16)
+ A 14 21
Spec : 5V
Open circuit or Replace or repair S B 15
NO poor connection - C 16 23
between CN-7
(14)-CN-52 (21) CN-142
CN-7 CN-51
or CN-7 (16 )-
CN-51 (20)
3009SH6MS32
6-85
ground.
copper. PIN

CN-51 Female
12 1
24 23 13
36 25
GROUND
Multimeter
3009SH6MS33
6-86
5. AUTO DECEL SYSTEM DOES NOT WORK
Cause Remedy
YES
YES
Defective travel Replace
Check voltage
NO pressure switch
between CD-6(A)
and (C)
NO
SPEC : connection
Check voltage between
Key ON : 24±2V
between CN-51 CN-51(7)-CD-6(A)
(8)-GND
and / or CN-51(13)-
CD-6(C)
SPEC :
Actuator operating : 1~5V
See TEST 7 YES
Defective work Replace
Check voltage
pressure sensor
between CD-7(A)
NO and (C)
NO
SPEC : connection
Key ON : 24±2V between
CN-51(7)-CD-7(A)
and / or CN-51(1)-
CD-7(C)
Wiring diagram
MCU
1 CD-6
7 A SUPPLY
8 B SIG
13 C RETURN
TRAVEL PRESSURE SENSOR
CN-51
CD-7
A SUPPLY
B SIG
C RETURN
WORK PRESSURE SENSOR
3009SH6MS34
6-87
ground.
copper. MCU
② Insert prepared pin to rear side of PIN
connectors : One pin to (8) of CN-51. CN-50 CN-51

CN-51 Female
12 8 1
24 13
36 25
GROUND
Multimeter
3009SH6MS35
6-88
Cause Remedy
YES
YES
poor connection
between
CN-1(3)-GND (10)-CN-1(3)
See TEST 8 SPEC :
Key ON : 24±2V CD-42(B)

NO
NO CN-1(2)-(4) between
CD-42(A)-CN-1(2)
SPEC :
Key ON : 24±2V
or CD-42(C)-
CN-1(4)

NO poor connection
between CN-1(2)-
CN-51(7) or CN-1
(4) - CN-51(8)
Wiring diagram
MCU
CD-42
7 13 2 A SUPPLY
10 6 3 B SIG
8 15 4 C RETURN
CN-2 CN-1
CN-51
3009SH6MS36
6-89
ground.
copper. PIN

CN-51 Female
12 10 1
24 13
36 25
GROUND
Multimeter
3009SH6MS37
6-90
Cause Remedy
YES
YES
poor connection
between
CN-1(1)-GND (11)-CN-1(1)
See TEST 9 SPEC :
Key ON : 24±2V CD-43(B)

NO
CD-43(A)-CN-1(2)
SPEC :
Key ON : 24±2V
or CD-43(C)-
CN-1(4)

NO poor connection
between CN-1(2)-
CN-51(7) or CN-1
(4) - CN-51(8)
Wiring diagram
MCU
CD-43
7 13 2 A SUPPLY
11 7 1 B SIG
8 15 4 C RETURN
CN-2 CN-1
CN-51
3009SH6MS38
6-91
ground.
copper. PIN

CN-51 Female
12 11 1
24 13
36 25
GROUND
Multimeter
3009SH6MS39
6-92
Cause Remedy
YES
YES
poor connection
between
CN-1(5)-GND (12)-CN-1(5)
See TEST 10 SPEC :
Key ON : 24±2V CD-44(B)

NO
CD-44(A)-CN-1(2)
SPEC :
Key ON : 24±2V
or CD-44(C)-
CN-1(4)

NO poor connection
between CN-1(2)-
CN-51(7) or CN-1
(4) - CN-7(8)
Wiring diagram
MCU
CD-44
7 13 2 A SUPPLY
12 4 5 B SIG
8 15 4 C RETURN
CN-2 CN-1
CN-51
3009SH6MS40
6-93
ground.
copper. PIN

CN-51 Female
12 11 1
24 13
36 25
GROUND
Multimeter
3009SH6MS41
6-94
9. MALFUNCTION OF POWER MAX
Cause Remedy
YES
connection between
YES Check resistance CN-88(1)-CN-50 (3)
between CN-88
(1)-(2)
Defective power
NO
YES Check resistance SPEC: 15-35Ω max. solenoid valve Repair or replace
between CN-51 See TEST 12 Check hydraulic
(2)-GND
system
Is voltage between Short circuit or poor Repair or replace

NO
CN-88(2)-GND connection between
SPEC : Power max button pressed ON : 0Ω
normal? Power max button released OFF : ∞ Ω CN-51(2)-CS-29
SPEC
KEY ON : 24±1V
KEY OFF : 0V Short circuit or poor Repair or replace
See TEST 11 NO
connection between
CN-88(2)-
Fuse No. 25
Wiring diagram
MCU
CN-88
3 1
2
CN-50
POWER MAX SOLENOID
2 5
FUSE
6
NO.25
CN-51 CN-4
CS-29
1
2
POWER MAX SWITCH
3009SH6MS42
6-95
2) TEST PROCEDURE SPEC : Key ON : 24±1V
Key OFF : 0V
(1) Test 11:
11 Check voltage between connector
CN-88(2) - GND.
① Disconnect connector CN-88 from power
max solenoid valve. Power max switch
② Start key ON.
③ Check voltage as figure.
LH RCV-lever
CN-88
Power max
solenoid valve
2 1
1 2
GROUND
Multimeter
21096MS14A
(2) Test 12:

12 Check resistance of the solenoid SPEC : 15~35Ω
valve between CN-88(1)-(2).
Power max switch
② Disconnect connector CN-88 from power
max solenoid valve.
③ Check resistance as figure.
LH RCV-lever
CN-88
Power max 2 1
solenoid valve
1 2
Multimeter
21096MS14B
6-96
10. MALFUNCTION OF BOOM PRIORITY EPPR VALVE
Cause Remedy
YES
connection between
CN-50(1)-CN-133
Check resistance (1) or Fuse No. 25
between CN-133(2)
CN-133(1)-(2)
SPEC : 15~35V
KEY : ON
Defective EPPR Repair or replace
NO
valve
Wiring diagram
MCU
CN-133
1 1
BOOM PRIORITY
EPPR VALVE
FUSE
NO.25
CN-50
3009SH6MS43
6-97
Group 1 Operational Performance Test ------------------------------------------------------------------------- 7-1

Group 2 Major Components ------------------------------------------------------------------------------------------- 7-23
Group 3 Track and Work Equipment ------------------------------------------------------------------------------ 7-32
GROUP 1 OPERATIONAL PERFORMANCE TEST
1. PURPOSE
Performance tests are used to check:
1) OPERATIONAL PERFORMANCE OF A
NEW MACHINE
Whenever a new machine is delivered in
Working
parts and reassembled at a customer's condition
site, it must be tested to confirm that the
operational performance of the machine
meets Hyundai spec.
2) OPERATIONAL PERFORMANCE OF A Maintenance
WORKING MACHINE record
With the passage of time, the machine's
operational performance deteriorates, so
that the machine needs to be serviced
periodically to restore it to its original
performance level. Operating
Before servicing the machine, conduct
performance tests to check the extent of
deterioration, and to decide what kind of
service needs to be done (by referring to
the "Service Limits" in this manual).
21077MS01
3) OPERATIONAL PERFORMANCE OF A
REPAIRED MACHINE
After the machine is repaired or serviced, it
must be tested to confir m that its
operational performance was restored by
the repair and/or service work done.
7-1
2. TERMINOLOGY
1) STANDARD
Specifications applied to the brand-new
machine, components and parts.
21077MS02
2) SERVICE LIMIT
The lowest acceptable performance level.
When the perfor mance level of the
machine falls below this level, the machine
must be removed from work and repaired.
Necessary parts and components must be
replaced.
21077MS03
7-2
3. OPERATION FOR PERFORMANCE TESTS
1) Observe the following rules in order to carry
out performance tests accurately and safely.
(1) The machine

Repair any defects and damage found, such
as oil or water leaks, loose bolts, cracks and
so on, before starting to test.
(2) Test area
① Select a hard, flat surface.
② Secure enough space to allow the machine
to run straight more than 20 m, and to make
a full swing with the front attachment
extended.
③ If required, rope off the test area and
provide signboards to keep unauthorized
personnel away.
(3) Precautions
① Before starting to test, agree upon the
signals to be employed for communication
among coworkers. Once the test is started,
be sure to communicate with each other
using these signals, and to follow them
7-3
without fail.
② Operate the machine carefully and always
give first priority to safety.
③ While testing, always take care to avoid
accidents due to landslides or contact with
high voltage power lines. Always confirm
that there is sufficient space for full swings.
④ Avoid polluting the machine and the ground
with leaking oil. Use oil pans to catch
escaping oil. Pay special attention to this
when removing hydraulic pipings.
(4) Make precise measurements

① Accurately calibrate test instruments in
advance to obtain correct data.
② Carry out tests under the exact test
conditions prescribed for each test item.
③ Repeat the same test and confirm that the
test data obtained can be procured
r e p e a t e d l y. U s e m e a n va l u e s o f
measurements if necessary.
7-3
2) ENGINE SPEED (CLUSTER TYPE 1)
(1) Measure the engine speed at each power
mode
※ The engine speed at each power mode
must meet standard RPM; if not, all other
CLUSTER
operational performance data will be
unreliable. It is essential to perform this
test first.
(2) Preparation
① Warm up the machine, until the engine
coolant temperature reaches 50˚C or
more, and the hydraulic oil is 50±5˚C.
② Set the accel dial at 10 (max) position.
③ Push the H-mode switch and confirm
that the fuel injection pump governor Engine RPM display
lever comes into contact with the high- Power mode switch
idle stopper. Pilot lamp(P, S, E)
④ Measure the engine RPM.

(3) Measurement
① Start the engine. The engine will run at
start idle speed. Measure engine speed
with a engine rpm display.
② Measure and record the engine speed at
each mode (P, S, E).
③ Select the P-mode.
④ Lightly operate the bucket control lever a
few times, then return the control lever to
neutral; The engine will automatically
enter the auto-idle speed after 4
seconds. 3009S7MS01
⑤ Measure and record the auto deceleration

speed.
(4) Evaluation
The measured speeds should meet the following specifications.
Unit : rpm
Model Engine speed Standard Remarks
Start idle 1000±100
P mode 2100±50
S mode 2000±50
R330LC-9S
E mode 1900±50
Auto decel 1150±100
One touch decel 1000±100
Condition : Set the accel dial at 10 (max) position.
7-4
■ ENGINE SPEED (CLUSTER TYPE 2)
(1) Measure the engine speed at each power
mode CLUSTER
※ The engine speed at each power mode
must meet standard RPM; if not, all other
operational performance data will be
unreliable. It is essential to perform this
test first.
(2) Preparation
① Warm up the machine, until the engine
coolant temperature reaches 50˚C or
more, and the hydraulic oil is 50±5˚C.
② Set the accel dial at 10 (max) position.
③ Push the H-mode switch and confirm
that the fuel injection pump governor
lever comes into contact with the high-
idle stopper. Power mode switch
④ Measure the engine RPM. Pilot lamp(H, S)
Engine RPM display
(3) Measurement
① Start the engine. The engine will run at
start idle speed. Measure engine speed
with a engine rpm display.
② Measure and record the engine speed at
each mode (M, H, S).
③ Select the M-mode.
④ Lightly operate the bucket control lever a
few times, then return the control lever to
neutral; The engine will automatically
enter the auto-idle speed after 4
seconds. 3009S7MS02
⑤ Measure and record the auto deceleration

speed.
(4) Evaluation
The measured speeds should meet the following specifications.
Unit : rpm
Model Engine speed Standard Remarks
Start idle 1000±100
M mode 2100±50
H mode 2000±50
R330LC-9S
S mode 1900±50
Auto decel 1150±50
One touch decel 1000±50
Condition : Set the accel dial at 10 (max) position.
7-5
3) TRAVEL SPEED
(1) Measure the time required for the
excavator to travel a 20 m test track.
(2) Preparation
① Adjust the tension of both tracks to be
equal.
② Prepare a flat and solid test track 20 m in
length, with extra length of 3 to 5 m on
0.3~0.5m
both ends for machine acceleration and
deceleration.
③ Hold the bucket 0.3 to 0.5 m above the
ground with the arm and bucket rolled in.
④ Keep the hydraulic oil temperature at
290LC7MS01
50±5˚C.
(3) Measurement
① Measure both the low and high speeds
of the machine.
② Before starting either the low or high
speed tests, adjust the travel mode
switch to the speed to be tested, then
select the following switch positions.
· Power mode switch :
P mode(Cluster type 1)
M mode(Cluster type 2) 3 ~ 5m 20m 3 ~ 5m
③ Star t traveling the machine in the
acceleration zone with the travel levers at
full stroke.
④ Measure the time required to travel 20 m.
⑤ After measuring the forward travel
290LC7MS02
speed, turn the upperstructure 180。and
measure the reverse travel speed.
⑥ Repeat steps ④ and ⑤ three times in
each direction and calculate the average
values.
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds / 20 m
Model Travel speed Standard Maximum allowable Remarks
1 Speed 21.8±2.0 29.0
R330LC-9S
2 Speed 12.4±1.0 17.1
7-6
4) TRACK REVOLUTION SPEED
(1) Measure the track revolution cycle time
with the track raised off ground.
(2) Preparation
① Adjust the tension of both side tracks to
be equal.
② On the track to be measured, mark one 90~110
shoe with chalk.
③ Swing the upperstructure 90˚ and lower
the bucket to raise the track off ground.
Keep the boom-arm angle between 90 to Mark
110˚ as shown. Place blocks under
machine frame.
50±5˚C.
21077MS06
(3) Measurement
① Select the following switch positions.
· Travel mode switch : 1 or 2 speed
M mode(Cluster type 2)
· Auto decel switch : OFF
② Operate the travel control lever of the
raised track in full forward and reverse.
③ Rotate 1 turn, then measure time taken
for next 3 revolutions.
④ Raise the other side of machine and
repeat the procedure.
⑤ Repeat steps ③ and ④ three times and
calculate the average values.
(4) Evaluation
The revolution cycle time of each track should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Travel speed Standard Maximum allowable
1 Speed 33.5±2.0 41.8
R330LC-9S
2 Speed 19.2±2.0 24.0
7-7
5) TRAVEL DEVIATION
(1) Measure the deviation by the tracks from
a 20m straight line.
(2) Preparation
① Adjust the tension of both tracks to be
equal.
② Provide a flat, solid test yard 20 m in
length, with extra length of 3 to 5 m on 0.3~0.5m
both ends for machine acceleration and
deceleration.
③ Hold the bucket 0.3 to 0.5 m above the
ground with the arm and bucket rolled in.
290LC7MS01
50±5˚C.
(3) Measurement
① Measure the amount of mistracking at
high and low travel speeds.
② Before beginning each test, select the
following switch positions. 3~5 m extra length
· Power mode switch : a
M
20
M mode(Cluster type2)
③ Star t traveling the machine in the 3~5 m extra length
acceleration zone with the travel levers at
full stroke.
④ Measure the distance between a straight
20m line and the track made by the 7-7(2)
machine. (dimension a)
⑤ After measuring the tracking in forward
travel, turn the upperstructure 180˚ and
measure that in reverse travel.
⑥ Repeat steps ④ and ⑤ three times and
(4) Evaluation
Mistrack should be within the following specifications.
Unit : mm / 20 m
Model Standard Maximum allowable Remarks
R330LC-9S 200 below 250
7-8
6) SWING SPEED
(1) Measure the time required to swing three
complete turns.
(2) Preparation
① Check the lubrication of the swing gear
and swing bearing.
② Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
③ With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin. The bucket must be empty.
50±5˚C.
290LC7MS03
(3) Measurement
· Power mode switch: Each mode
② Operate swing control lever fully.
③ Swing 1 turn and measure time taken to
swing next 3 revolutions.
④ Repeat steps ② and ③ three time and
(4) Evaluation
The time required for 3 swings should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Power mode switch Standard Maximum allowable
P mode (Cluster type 1)
R330LC-9S 18.8±1.5 23.5
M mode (Cluster type 2)
7-9
7) SWING FUNCTION DRIFT CHECK
(1) Measure the swing drift on the bearing
outer circumference when stopping after
a 360˚ full speed swing.
(2) Preparation
① Check the lubrication of the swing gear
and swing bearing.
② Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
③ With the arm rolled out and bucket rolled
the bucket pin is the same as the boom 290LC7MS03
foot pin. The bucket must be empty.
④ Make two chalk marks: one on the swing
bearing and one directly below it on the
track frame.
⑤ Swing the upperstructure 360˚.
⑥ Keep the hydraulic oil temperature at
50±5˚C.
(3) Measurement
① Conduct this test in the P mode.(M mode)
② Select the following switch positions.
③ Operate the swing control lever fully and
return it to the neutral position when the
mark on the upperstructure aligns with
that on track frame after swinging 360˚. Drift angle
④ Measure the distance between the two
360 swing
marks.
Swing start & stop
⑤ Align the marks again, swing 360˚, then
test the opposite direction.
21077MS08
⑥ Repeat steps ④ and ⑤ three times each
and calculate the average values.
(4) Evaluation
The measured drift angle should be within the following specifications.
Unit : Degree
Model Power mode switch Standard Maximum allowable Remarks
P mode
R330LC-9S 90 below 112.5
M mode
7-10
8) SWING BEARING PLAY
(1) Measure the swing bearing play using a
dial gauge to check the wear of bearing
races and balls.
(2) Preparation
① Check swing bearing mounting cap
screws for loosening.
② Check the lubrication of the swing
bearing. Confirm that bearing rotation is
smooth and without noise.
③ Install a dial gauge on the track frame as
shown, using a magnetic base.
④ Position the upperstructure so that the
7-10(1)
boom aligns with the tracks facing
towards the front idlers.
⑤ Position the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
⑥ Bucket should be empty.
(3) Measurement Measurement : (h1)
① With the arm rolled out and bucket rolled
in, hold the bottom face of the bucket to
the same height of the boom foot pin.
Record the dial gauge reading (h1).
② Lower the bucket to the ground and use
it to raise the front idler 50cm.
Measurement : (h2)
Record the dial gauge reading (h2).
③ Calculate bearing play(H) from this data
(h1 and h2) as follows.
H=h2-h1
(4) Evaluation 290LC7MS04
The measured drift should be within the following specifications.
Unit : mm
Model Standard Maximum allowable Remarks
R330LC-9S 0.5 ~ 1.5 3.0
7-11
9) HYDRAULIC CYLINDER CYCLE TIME
(1) Measure the cycle time of the boom,
standard arm, and standard bucket
cylinders.
(2) Preparation Boom cylinder
① To measure the cycle time of the boom Raise
cylinders:
With the arm rolled out and the empty
bucket rolled out, lower the bucket to the
ground, as shown. Lower
② To measure the cycle time of the arm
cylinder.
With the empty bucket rolled in, position
Arm cylinder
the arm so that it is vertical to the ground.
Lower the boom until the bucket is 0.5 m
above the ground. Roll out Roll in
③ To measure the cycle time of the bucket
cylinder.
90
The empty bucket should be positioned 0.5m
at midstroke between roll-in and roll-out,
so that the sideplate edges are vertical to
the ground. Bucket cylinder
50±5˚C.
(3) Measurement
· Power mode switch : Roll out Roll in
P mode(Cluster type 1) 0.5m
② To measure cylinder cycle times.
21077MS10
- Boom cylinders.
Measure the time it takes to raise the
boom, and the time it takes to lower the
boom. To do so, position the boom at
one stroke end then move the control
lever to the other stroke end as quickly
as possible.
- Arm cylinder.
Measure the time it takes to roll in the
arm, and the time it takes to roll out the
arm. To do so, position the bucket at
one stroke end, then move the control
as possible.
7-12
- Bucket cylinders
Measure the time it takes to roll in the
bucket, and the time it takes to roll out
the bucket. To do so, position the bucket
at one stroke end, then move the control
as possible.
- Repeat each measurement 3 times and
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds
Model Function Standard Maximum allowable Remarks

Boom raise 4.0±0.4 5.0
Boom lower 3.4±0.4 4.4
Arm in Regen ON 3.5±0.4 4.6
R330LC-9S
Arm out 3.3±0.3 4.1
Bucket load 2.8±0.4 3.4
Bucket dump 2.5±0.3 2.9
7-13
10) DIG FUNCTION DRIFT CHECK
(1) Measure dig function drift, which can be
caused by oil leakage in the control valve
and boom, standard arm, and standard
bucket cylinders, with the loaded bucket.
When testing the dig function drift just
after cylinder replacement, slowly operate
each cylinder to its stroke end to purge air.
(2) Preparation
① Load bucket fully. Instead of loading the
bucket, weight (W) of the following
specification can be used.
· W=M3×1.5
Where :
M3 = Bucket heaped capacity (m3)
1.5= Soil specific gravity
② Position the arm cylinder with the rod 20
to 30 mm extended from the fully retracted
position.
③ Position the bucket cylinder with the rod
20 to 30 mm retracted from the fully
extended position.
290LC7MS05
④ With the arm rolled out and bucket rolled
the bucket pin is the same as the boom
foot pin.
⑤ Keep the hydraulic oil temperature at
50±5˚C.
(3) Measurement
① Stop the engine.
② Five minutes after the engine has been
stopped, measure the changes in the
positions of the boom, arm and bucket
cylinders.
③ Repeat step ② three times and calculate
the average values.
(4) The measured drift should be within the following specifications.
Unit : mm / 5 min
Model Drift to be measured Standard Maximum allowable Remarks
Boom cylinder 10 below 20

R330LC-9S Arm cylinder 10 below 20
Bucket cylinder 40 below 50
7-14
11) CONTROL LEVER OPERATING FORCE
(1) Use a spring scale to measure the
maximum resistance of each control lever
at the middle of the grip.
(2) Preparation
① Keep the hydraulic oil temperature at
50±5˚C.
(3) Measurement
① Start the engine.
② Select the following switch positions.
③ Operate each boom, arm, bucket and
swing lever at full stroke and measure the
maximum operating force for each.
④ Lower the bucket to the ground to raise
one track off the ground. Operate the
travel lever at full stroke and measure the
maximum operating force required.
When finished, lower the track and then
jack-up the other track.
⑤ Repeat steps ③ and ④ three times and
(4) Evaluation
The measured operating force should be within the following specifications.
Unit : kgf
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 1.6 or below 2.0

Arm lever 1.6 or below 2.0
R330LC-9S Bucket lever 1.6 or below 2.0
Swing lever 1.6 or below 2.0
Travel lever 2.1 or below 3.15
7-15
12) CONTROL LEVER STROKE
(1) Measure each lever stroke at the lever top
using a ruler.
※ When the lever has play, take a half of this
value and add it to the measured stroke.
(2) Preparation
Keep the hydraulic oil temperature at
50±5˚C.
(3) Measurement
② Measure each lever stroke at the lever
top from neutral to the stroke end using a
ruler.
③ Repeat step ② three times and calculate
the average values.
(4) Evaluation
The measured drift should be within the following specifications.
Unit : mm
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 102±10 128

Arm lever 102±10 128
R330LC-9S Bucket lever 90±10 113
Swing lever 90±10 113
Travel lever 142±10 178
7-16
13) PILOT PRIMARY PRESSURE (CLUSTER TYPE 1)
(1) Preparation a3
Main pump

50±5˚C.
Pressure sensor
(2) Measurement
· Power mode switch : P mode
Cluster
② Measure the primary pilot pressure by
the monitoring menu of the cluster.
29097MS13
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
R330LC-9S P mode 40 +20 -
■ PILOT PRIMARY PRESSURE (CLUSTER TYPE 2)

(1) Preparation
② Push the pressure release button to
bleed air.
a3
③ Loosen and remove plug on the pilot
pump delivery port and connect pressure
gauge.
④ Star t the engine and check for oil
leakage from the port.
50±5˚C.
2507A7MS02A
(2) Measurement
· Power mode switch : M mode
② Measure the primary pilot pressure in the
M mode.
(3) Evaluation
Unit : kgf / cm2
R330LC-9S M mode 40 +20 -
7-17
14) FOR TRAVEL SPEED SELECTING PRESSURE
(1) Preparation
② Remove the top cover of the hydraulic
tank oil supply port with a wrench.
③ Push the pressure release button to
bleed air.
④ To measure the speed selecting pressure:
Install a connector and pressure gauge
assembly to turning joint P port as shown.
⑤ Star t the engine and check for on
leakage from the adapter.
50±5˚C.
(2) Measurement
Travel mode switch : 1 speed, 2 speed
· Mode selector :
② Measure the travel speed selecting
pressure in the Hi or Lo mode.
③ Lower the bucket to the ground to raise
the track off the ground. Operate the
travel lever at full stroke and measure the
fast speed pressure.
④ Repeat steps ② and ③ three times and
(3) Evaluation
The average measured pressure should be within the following specifications.
Unit : kgf / cm 2
Model Travel speed Standard Maximum allowable Remarks
1 Speed 0 -
R330LC-9S
2 Speed 40±5 -
7-18
15) SWING PARKING BRAKE RELEASING PRESSURE
(1) Preparation
② Remove the top cover of the hydraulic
tank oil supply port with a wrench.
③ The pressure release L wrench to bleed
air.
④ Install a connector and pressure gauge
assembly to swing motor SH port, as
shown.
⑤ Star t the engine and check for oil SH
leakage from the adapter.

50±5˚C.
(2) Measurement
② Operate the swing function or arm roll in
function and measure the swing brake
29097MS03
c o n t r o l p r e s s u r e w i t h t h e b ra ke
disengaged. Release the control lever to
return to neutral and measure the control
pressure when the brake is applied.
Repeat step ② three times and calculate
the average values.
(3) Evaluation
Unit : kgf / cm2
Model Description Standard Allowable limits Remarks
Brake disengaged 40 Over 9
R330LC-9S
Brake applied 0 -
7-19
16) MAIN PUMP DELIVERY PRESSURE (CLUSTER TYPE 1)
(1) Preparation Main pump
50±5˚C.
Pressure sensor a1
(2) Measurement a2

· Power mode switch : P mode
② Measure the main pump deliver y
pressure by the monitoring menu of the
cluster. Cluster
(3) Evaluation 29097MS14
The average measured pressure should meet the following specifications.

Unit : kgf / cm2
R330LC-9S High ilde 40±5 -
■ MAIN PUMP DELIVERY PRESSURE (CLUSTER TYPE 2)

(1) Preparation
bleed air.
③ Loosen and remove pump pressure.
assembly main pump gauge port as
shown.
290LC7MS07
50±5˚C.
(2) Measurement
· Mode selector : M mode
② Measure the main pump deliver y
pressure in the M mode (high idle).
(3) Evaluation
Unit : kgf / cm2
R330LC-9S High idle 40±5 -
7-20
17) SYSTEM PRESSURE REGULATOR RELIEF SETTING (CLUSTER TYPE 1)
(1) Preparation
50±5˚C. Main pump
(2) Measurement
① Select the following switch positions. Pressure sensor a1
· Power mode switch : P mode a2
② Slowly operate each control lever of

boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
Cluster
③ In the swing function, place bucket
against an immovable object and
measure the relief pressure.
④ In the travel function, lock undercarriage
with an immovable object and measure 29097MS14
the relief pressure.

(3) Evaluation
Unit : kgf / cm2
Model Function to be tested Standard Remark

Boom, Arm, Bucket 350(380)±10 400±10 (Port relief)
R330LC-9S Travel 350±10 -
Swing 300±10 -
( ) : Power boost
7-21
■ SYSTEM PRESSURE REGULATOR RELIEF SETTING (CLUSTER TYPE 2)
(1) Preparation
bleed air.
③ To measure the system relief pressure.
assembly main pump gauge port, as
shown.
50±5˚C.
(2) Measurement
· Mode selector : M mode 2507A7MS03A
② Slowly operate each control lever of

boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
③ In the swing function, place bucket
against an immovable object and
measure the relief pressure.
④ In the travel function, lock undercarriage
with an immovable object and measure
the relief pressure.
(3) Evaluation
Unit : kgf / cm2
Model Function to be tested Standard Remark

Boom, Arm, Bucket 350(380)±10 400±10 (Port relief)
R330LC-9S Travel 350±10 -
Swing 300±10 -
( ) : Power boost
7-22
GROUP 2 MAJOR COMPONENT
1. MAIN PUMP
3 1 2
9 6 5 4 7
290LC7MS08
Standard Recommended
Part name & inspection item replacement Counter measures
dimension value
Clearance
between piston(1) & Replace piston
d D 0.043 0.070 or cylinder.
cylinder bore(2)
(D-d)
Play between
piston(1) & shoe caulking
0-0.1 0.3
section(3)
(δ) Replace
assembly of
Thickness of shoe δ piston & shoe.
(t) t 5.4 5.0
Free height of cylinder

spring(4) Replace cylinder
47.9 47.1 spring.
(L)
L
Combined height of set

plate(5) & spherical Replace
23.8 22.8 retainer or set
bushing(6) h H
(H-h) plate.
Surface roughness for Surface roughness

necessary to be corrected 3z
valve plate (sliding face)
(7,8), swash plate (shoe Lapping
plate area) (9), & Standard surface roughness
0.4z or lower
cylinder(2) (sliding face) (corrected value)
7-23
2. MAIN CONTROL VALVE
Part name Inspection item Criteria & measure
Casing · Existence of scratch, rusting or corrosion. · In case of damage in following section,

replace part
- Sliding sections of casing fore and spool,
especially land sections applied with
holding pressure
- Seal pocket section where spool is
inserted
- Seal section of por t where O-ring
contacts
- Seal section of each relief valve for main,
travel, and port
- Other damages that may damage
normal functions
Spool · Existence of scratch, gnawing, rusting or · Replacement when its outside sliding
corrosion. section has scratch (especially on seals
contacting section)
· Insert spool in casing hole, rotate and · Correction or replacement when O-ring is
reciprocate it. damaged or when spool does not move
smoothly
Load check valve · Damage of load check valve or spring · Repair or replace of improper seat contact
Around spring · Rusting, corrosion, deformation or · Replacement for significant damage

breaking of spring, spring seat, plug or
cover.
Around seal · External oil leakage. · Replacement

for spool
Main relief valve, · External rusting or damage. · Replacement

Over relief valve · Contacting face of valve seat. · Replacement when damaged
7-24
3. SWING DEVICE
1) WEARING PARTS
Inspection item replacement Counter measures
dimension value
Replace piston or
Clearance between piston and cylinder block bore 0.028 0.058
cylinder block
Replace assembly
Play between piston and shoe caulking section (δ) 0 0.3
of piston and shoe
Replace assembly
Thickness of shoe (t) 5.5 5.3
of piston and shoe
Replace set of
Combined height of retainer plate and spherical
6.5 6.0 retainer plate and
bushing (H-h)
sperical bushing
Thickness of friction plate 4.0 3.6 Replace
H
h
t
δ
2) SLIDING PARTS
Part name Standard roughness Allowable roughness Remark
0.8-Z (Ra=0.2)
Shoe 3-Z (Ra=0.8)
(LAPPING)
0.4-Z (Ra=0.1)
Shoe plate 3-Z (Ra=0.8)
(LAPPING)
1.6-Z (Ra=0.4)
Cylinder 12.5-Z (Ra=3.2)
(LAPPING)
0.8-Z (Ra=0.2)
Valve plate 6.3-Z (Ra=1.6)
(LAPPING)
7-25
4. TRAVEL MOTOR
1) WEARING PARTS
Inspection item replacement Counter measures
dimension value
Replace piston or
Clearance between piston and cylinder block bore 0.028 0.058
cylinder block
Replace assembly
Play between piston and shoe caulking section(T) 0 0.3
of piston and shoe
Replace assembly
Thickness of shoe(t) 5.5 5.3
of piston and shoe
Replace set of set

Combined height of set plate and ball guide(H-h) 6.5 6.0 plate and ball
guide
Thickness of friction plate 4.0 3.6 Replace
2) SLIDING PARTS
Part name Standard roughness Remark
Shoe 0.8S -
Shoe plate 0.4S -
Cylinder 1.6S -
Valve plate 0.8S -
7-26
5. TRAVEL REDUCTION GEAR
The followings are the general maintenance standards. However, it is most important to determine
which parts should be replaced, depending on the characteristics shown before disassembling,
damages or discoloration of exterior view, the purpose of disassembling, the expected remaining
service life etc..
Item Part name Criteria Allowable limit Remedy
Smooth, without abnor- Replace 3 pieces as a

A Wear of planetary shaft mal wear or seizure set
Smooth, without abnor- Not over 1.6 of pitch- Replace 3 pieces as a
B Condition of tooth surface mal wear or seizure ing, no cracks at root set for planetary pinion
Thrust clearance of angular Adjust shim thickness
C -0.08~0.02 mm
bearings (2) Refer to 8-101 (5)
D Thickness of thrust washer 1 (18) 3.3~3.7 mm Wear 0.1 mm Replace
E Thickness of thrust washer 2 (11) 5.3~5.7 mm Wear 0.1 mm Replace
F Thickness of thrust plate (23) 4.34~4.66 mm Wear 0.15 mm Replace
G Lubrication oil 2000 working hours (machine hour meter) Replace
D F C
29097MS11
7-27
6. RCV LEVER
Maintenance
Criteria Remark
check item
Leakage The valve is to be replaced when the leakage Conditions :

becomes more than 1000 cc/m at neutral handle Primary pressure : 30 kgf/cm2
position, or more than 2000 cc/m during operation. Oil viscosity : 23 cSt
Spool This is to be replaced when the sliding surface has The leakage at the left condition is
worn more than 10μm, compared with the non- estimated to be nearly equal to the
sliding surface. above leakage.
Push rod
Ø7
1 mm
This is to be replaced when the top end has worn

more than 1 mm.
Play at operating The pin, shaft, and joint of the operating section are When a play is due to looseness of a
section to be replaced when their plays become more than tightened section, adjust it.
2 mm due to wears or so on.
Operation stability When abnormal noises, hunting, primary pressure

drop, etc. are generated during operation, and
these cannot be remedied, referring to section 6.
Troubleshooting, replace the related parts.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
2. When loosening the hexagon socket head cap screw (125), replace the seal washers (121)
without fail.
7-28
7. RCV PEDAL
Maintenance
Criteria Remark
check item
Leakage The valve is to be replaced when the leakage effect Conditions :

to the system. For example, the primary pressure Primary pressure : 30 kgf/cm2
drop. Oil viscosity : 23 cSt
Spool This is to be replaced when the sliding surface has The leakage at the left condition is
worn more than 10μm, compared with the non- estimated to be nearly equal to the
sliding surface. above leakage.
Push rod
Ø7
1 mm
This is to be replaced when the top end has worn

more than 1 mm.
Play at operating The pin, shaft, and joint of the operating section are When a play is due to looseness of a
section to be replaced when their plays become more than tightened section, adjust it.
2 mm due to wears or so on.
Operation stability When abnormal noises, hunting, primary pressure

drop, etc. are generated during operation, and
these cannot be remedied, referring to section 6.
Troubleshooting, replace the related parts.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling.

However, they may be reused, after being confirmed to be free of damage.
7-29
8. TURNING JOINT
Part name Maintenance standards Remedy
Sliding surface Plating worn or peeled due to seizure or contamination. Replace

with sealing
sections.
Sliding surface ·Worn abnormality or damaged more than 0.1 mm Replace

between body and (0.0039 in) in depth due to seizure contamination.
Body, stem other than
Stem sealing section. ·Damaged more than 0.1 mm (0.0039 in) in depth. Smooth with oilstone.
Sliding surface ·Worn more than 0.5 mm (0.02 in) or abnormality. Replace
with thrust plate.
·Worn less than 0.5 mm (0.02 in). Smooth
·Damage due to seizure or contamination remediable Smooth

within wear limit (0.5 mm) (0.02 in).
Cover Sliding surface ·Worn more than 0.5 mm (0.02 in) or abnormality. Replace
with thrust plate.
·Worn less than 0.5 mm (0.02 in). Smooth
·Damage due to seizure or contamination remediable Replace

within wear limit (0.5 mm) (0.02 in).
·Extruded excessively from seal groove square ring. Replace
- Extrusion
Square ring
·Slipper ring 1.5 mm (0.059 in) narrower than seal Replace

groove, or narrower than back ring.
Seal set -
1.5 mm (max.)
(0.059 in)
·Worn more than 0.5 mm (0.02 in) ~ 1.5 mm (MAX.) Replace

(0.059 in)
-
7-30
9. CYLINDER
Part name Inspecting section Inspection item Remedy
Piston rod ·Neck of rod pin ·Presence of crack ·Replace

·Weld on rod hub ·Presence of crack ·Replace
·Stepped part to which piston ·Presence of crack ·Replace
is attached.
·Threads ·Presence of crack ·Recondition or replace
·Plated surface ·Plating is not worn off to ·Replace or replate
base metal.
·Rust is not present on plating. ·Replace or replate
·Scratches are not present. ·Recondition, replate or replace
·Rod ·Wear of O.D. ·Recondition, replate or replace
·Bushing at mounting part ·Wear of I.D. ·Replace
Cylinder tube ·Weld on bottom ·Presence of crack ·Replace
·Weld on head ·Presence of crack ·Replace
·Weld on hub ·Presence of crack ·Replace
·Tube interior ·Presence of faults ·Replace if oil leak is seen
·Bushing at mounting part ·Wear on inner surface ·Replace
Gland ·Bushing ·Flaw on inner surface ·Replace if flaw is deeper
than coating
7-31
GROUP 3 TRACK AND WORK EQUIPMENT
1. TRACK
1) TRACK ROLLER
2
1
3 4
21037MS01
Unit : mm
No. Check item Criteria Remedy
Standard size Repair limit

1 Outside diameter of flange
Ø216 -
Rebuild or
2 Outside diameter of tread Ø180 Ø168 replace
3 Width of tread 50 56
4 Width of flange 57 21
Standard size & tolerance Standard Clearance
5 Clearance between shaft Shaft Hole clearance limit Replace
and bushing 0 +0.05 bushing
Ø75 -0.03 Ø75.35 0 0.35 to 0.40 2.0
Side clearance of roller Standard clearance Clearance limit

6 Replace
(both side) 0.16~1.24 2.0
7-32
2) CARRIER ROLLER
4 3
6
1
2
32037MA37
Unit : mm

1 Outside diameter of flange
Ø200 -
Rebuild or
2 Outside diameter of tread Ø168 Ø158 replace
3 Width of tread 54 59
4 Width of flange 19 -
Standard size & tolerance Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
5
and bushing +0.085 +0.37 0.245 bushing
Ø55 +0.066 Ø55 +0.33 to 0.304
2.0
Clearance between shaft 0 +0.5

6 Ø58 -0.1 Ø58 +0.3 0.3 to 0.6 1.2 Replace
and support
7-33
3) IDLER
8
1
2
7
3 5
4
21037MS03
Unit : mm

1 Outside diameter of protrusion
Ø646 Ø636
2 Outside diameter of tread Ø594 Ø588 Rebuild or
3 Width of protrusion 102 92 replace
4 Total width 203 -

5 Width of tread 50.5 56.5
Standard size & tolerance
Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
6 and bushing
0 +0.05 bushing
Ø90 -0.035 Ø90.35 0 0.35 to 0.435 2.0
Clearance between shaft 0 +0.09

7 and support Ø90 -0.035 Ø90 +0.036 0.036 to 0.125 1.2 Replace
Side clearance of idler Standard clearance Clearance limit

8 Replace
(both side) 0.4 to 1.2 2.0
7-34
4) TRACK
2 1
4
3
5
21037MS04
Unit : mm
Standard size Repair limit Turn or

1 Link pitch replace
216 223
2 Outside diameter of bushing Ø66.5 Ø58.5
Rebuild or
3 Height of grouser 30 21 replace
4 Height of link 116 104
5 Tightening torque Initial tightening torque : 115±5 kgf·m Retighten
7-35
5) TRACK FRAME AND RECOIL SPRING
2
3
1
21037MS05
Unit : mm
Standard size Tolerance Repair limit
Track frame 132 +2

1 Vertical width of idler guide 0 138
0 Rebuild or
Idler support 130 - 1.5 124
replace
+2
Track frame 292 298
0
2 Horizontal width of idler guide
Idler support 290 - 286

Free Installation Installation Free Installation
3 Recoil spring Replace
length length load length load
Ø253×710 580 19012 kg - 15210 kg
7-36
2. WORK EQUIPMENT
A C D E F
B K J I H G
21077MS20
Unit : mm
Pin Bushing
Measuring point Normal Remedy
Mark Recomm. Recomm. &
(Pin and Bushing) value service Limit service Limit
of use of use Remark
limit limit
A Boom Rear 110 109 108.5 110.5 111 Replace
B Boom Cylinder Head 100 99 98.5 100.5 101 〃
C Boom Cylinder Rod 100 99 98.5 100.5 101 〃
D Arm Cylinder Head 100 99 98.5 100.5 101 〃
E Boom Front 100 99 98.5 100.5 101 〃
F Arm Cylinder Rod 100 99 98.5 100.5 101 〃
G Bucket Cylinder Head 90 89 88.5 90.5 91 〃
H Arm Link 90 89 88.5 90.5 91 〃
I Bucket and Arm Link 100 99 98.5 100.5 101 〃
J Bucket Cylinder Rod 90 89 88.5 90.5 91 〃
K Bucket Link 100 99 98 100.5 101 〃
7-37
Group 1 Precaution --------------------------------------------------------------------------------------------------------- 8-1

Group 2 Tightening Torque --------------------------------------------------------------------------------------------- 8-4
Group 7 RCV Lever --------------------------------------------------------------------------------------------------------- 8-112
Group 8 Turning Joint ------------------------------------------------------------------------------------------------------ 8-126
Group 9 Boom, Arm and Bucket Cylinder --------------------------------------------------------------------- 8-131
Group 11 Work Equipment ----------------------------------------------------------------------------------------------- 8-160
GROUP 1 PRECAUTIONS
1. REMOVAL WORK
1) Lower the work equipment completely to the ground.
If the coolant contains antifreeze, dispose of it correctly.
2) After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
3) When draining oil, prepare a container of adequate size to catch the oil.
4) Confirm the match marks showing the installation position, and make match marks in the
necessary places before removal to prevent any mistake when assembling.
5) To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
6) Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
7) Check the number and thickness of the shims, and keep in a safe place.
8) When raising components, be sure to use lifting equipment of ample strength.
9) When using forcing screws to remove any components, tighten the forcing screws alternately.
10) Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
11) When removing hydraulic equipment, first release the remaining pressure inside the hydraulic tank
and the hydraulic piping.
12) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
number D d L
06 6 5 8
08 8 6.5 11
10 10 8.5 12
12 12 10 15
14 14 11.5 18 Taper 1/8
ØD Ød
16 16 13.5 20
18 18 15 22
20 20 17 25
L
22 22 18.5 28
24 24 20 30
27 27 22.5 34
8-1
2. INSTALL WORK
1) Tighten all bolts and nuts (sleeve nuts) to the specified torque.
2) Install the hoses without twisting or interference.
3) Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
4) Bend the cotter pin or lock plate securely.
5) When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2-3 drops of adhesive.
6) When coating with gasket sealant, clean the surface and remove all oil and grease, check that
there is no dirt or damage, then coat uniformly with gasket sealant.
7) Clean all parts, and correct any damage, dents, burrs, or rust.
8) Coat rotating parts and sliding parts with engine oil.
9) When press fitting parts, coat the surface with antifriction compound (LM-P).
10) After installing snap rings, check that the snap ring is fitted securely in the ring groove (check that
the snap ring moves in the direction of rotation).
11) When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
12) When using eyebolts, check that there is no deformation or deterioration, and screw them in fully.
13) When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
14) When operating the hydraulic cylinders for the first time after repairing and reassembling the
hydraulic cylinders, pumps, or other hydraulic equipment or piping, always bleed the air from the
hydraulic cylinders as follows:
(1) Start the engine and run at low idling.
(2) Operate the control lever and actuate the hydraulic cylinder 4-5 times, stopping 100mm before the
end of the stroke.
(3) Next, operate the piston rod to the end of its stroke to relieve the circuit. (The air bleed valve is
actuated to bleed the air.)
(4) After completing this operation, raise the engine speed to the normal operating condition.
※ If the hydraulic cylinder has been replaced, carry out this procedure before assembling the rod to
※ the work equipment.
Carry out the same operation on machines that have been in storage for a long time after
completion of repairs.
8-2
3. COMPLETING WORK
1) If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
2) If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
3) If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
4) Add the specified amount of grease (molybdenum disulphied grease) to the work equipment
related parts.
8-3
GROUP 2 TIGHTENING TORQUE
1. MAJOR COMPONENTS
Torque
No. Descriptions Bolt size
kgfÂm lbfÂft
1 Engine mounting bolt (engine-bracket) M12 Ý 1.75 10 Ü 1.0 72.3 Ü 7.2
2 Engine mounting bolt (bracket-frame) M24 Ý 3.0 90 Ü 7.0 651 Ü 51
3 Engine Radiator mounting bolt M16 Ý 2.0 29.7 Ü 4.5 215 Ü 32.5
4 Coupling mounting socket bolt M20 Ý 2.5 46.5 Ü2.5 336 Ü18.1
5 Fuel tank mounting bolt M20 Ý 2.5 57.9 Ü 8.7 419 Ü 62.9
6 Main pump housing mounting bolt M10 Ý 1.5 6.9 Ü 0.3 49.9 Ü 2.2
7 Main pump mounting socket bolt M20 Ý 2.5 42 Ü 4.5 304 Ü 32.5
Hydraulic
8 Main control valve mounting nut M12 Ý 1.75 12.3 Ü 1.3 89.0 Ü 9.4
system
9 Hydraulic oil tank mounting bolt M20 Ý 2.5 57.9 Ü 8.7 419 Ü 62.9
10 Turning joint mounting bolt, nut M12 Ý 1.75 12.3 Ü 1.3 89.0 Ü 9.4
11 Swing motor mounting bolt M20 Ý 2.5 57.9 Ü 8.7 419 Ü 62.9
12 Swing bearing upper part mounting bolt M24 Ý 3.0 97.8 Ü 10 707 Ü 72.3
Power
13 train Swing bearing lower part mounting bolt M24 Ý 3.0 97.8 Ü 10 707 Ü 72.3
system
14 Travel motor mounting bolt M24 Ý 3.0 84 Ü 8.0 608 Ü 57.8
15 Sprocket mounting bolt M20 Ý 2.5 57.9 Ü 6.0 419 Ü 43.4
16 Carrier roller mounting bolt, nut M16 Ý 2.0 29.7Ü 3.0 215 Ü 21.7
17 Track roller mounting bolt M20 Ý 2.5 57.9 Ü 6.0 419 Ü 43.4
Under
18 Track tension cylinder mounting bolt M12 Ý 1.25 15 Ü 5.0 108 Ü 36
carriage
19 Track shoe mounting bolt, nut M22 Ý 1.5 115 Ü 5.0 831 Ü 36
20 Track guard mounting bolt M20 Ý 2.5 46 Ü 5 333 Ü 36
21 Counterweight mounting bolt M36 Ý 3.0 308 Ü 46 2228 Ü 333
22 Others Cab mounting bolt M12 Ý 1.75 12.8 Ü 3.0 92.6 Ü 21.7
23 Operator's seat mounting bolt M 8 Ý 1.25 4.05 Ü 0.8 29.3 Ü 5.8
※ For tightening torque of engine and hydraulic components, see engine maintenance guide and
service manual.
8-4
2. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
8T 10T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft
M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7
M10×1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60.0
M12×1.75 7.4 ~ 11.2 53.5 ~ 81.0 9.8 ~ 15.8 70.9 ~ 114
M14×2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 163
M16×2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18×2.0 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 344
M20×2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22×2.5 48.3 ~ 63.3 349 ~ 458 65.8 ~ 98.0 476 ~ 709
M24×3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30×3.0 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1656
M36×4.0 174 ~ 236 1261 ~ 1704 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft
M 8×1.0 2.2 ~ 3.4 15.9 ~ 24.6 3.0 ~ 4.4 21.7 ~ 31.8
M10×1.2 4.5 ~ 6.7 32.5 ~ 48.5 5.9 ~ 8.9 42.7 ~ 64.4
M12×1.25 7.8 ~ 11.6 56.4 ~ 83.9 10.6 ~ 16.0 76.7 ~ 116
M14×1.5 13.3 ~ 18.1 96.2 ~ 131 17.9 ~ 24.1 130 ~ 174
M16×1.5 19.9 ~ 26.9 144 ~ 195 26.6 ~ 36.0 192 ~ 260
M18×1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20×1.5 40.0 ~ 54.0 289 ~ 391 53.4 ~ 72.2 386 ~ 522
M22×1.5 52.7 ~ 71.3 381 ~ 516 70.7 ~ 95.7 511 ~ 692
M24×2.0 67.9 ~ 91.9 491 ~ 665 90.9 ~ 123 658 ~ 890
M30×2.0 137 ~ 185 990 ~ 1339 182 ~ 248 1314 ~ 1796
M36×3.0 192 ~ 260 1390 ~ 1880 262 ~ 354 1894 ~ 2562
8-5
2) PIPE AND HOSE (FLARE TYPE)
Thread size (PF) Width across flat (mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130.2
1" 41 21 151.9
1-1/4" 50 35 253.2
3) PIPE AND HOSE (ORFS TYPE)
Thread size (UNF) Width across flat (mm) kgf·m lbf·ft
9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130.2
1-7/16-12 41 21 151.9
1-11/16-12 50 35 253.2
4) FITTING
Thread size Width across flat (mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130.2
1" 41 21 151.9
1-1/4" 50 35 253.2
8-6
GROUP 3 PUMP DEVICE
1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
(3) Loosen the breather slowly to release the 13031GE18
pressure inside the hydraulic tank.

Escaping fluid under pressure can
penetrate the skin causing serious injury.
(4) Remove the wirings for the pressure
sensors and so on.
13
(5) Loosen the drain plug under the hydraulic
tank and drain the oil from the hydraulic 1 13
tank. 2 12
3
·Hydraulic tank quantity : 190 ℓ
(6) Remove bolts (13) and disconnect pipe 29098MP01
(1,2).
(7) Disconnect pilot line hoses (4, 5, 6, 7, 8,
9, 10). 4
(8) Remove bolts(12) and disconnect pump 10
5
suction tube (3).
※ When pump suction tube is disconnected,
the oil inside the piping will flow out, so
6
catch it in oil pan.
7
8
(9) Sling the pump assembly and remove the
pump mounting bolts. 9
29098MP02
·Weight : 140 kg (310 lb)
※ Pull out the pump assembly from housing.
When removing the pump assembly,
check that all the hoses have been
disconnected.
8-7
2) INSTALL
(1) Carry out installation in the reverse order
to removal
(2) Remove the suction strainer and clean it.
(3) Replace the return filter with a new one.
(4) Remove breather and clean it.
(5) After adding oil to the hydraulic tank to
the specified level.
(6) Bleed the air from the hydraulic pump.
① Remove the air vent plug (2EA)
② Tighten plug lightly
③ Start the engine, run at low idling, and
check oil come out from plug.
④ Tighten plug.
(7) Start the engine, run at low idling (3~5

minutes) to circulate the oil through the
system.
(8) Confirmed the hydraulic oil level and
check the hydraulic oil leaks or not.
8-8
2. MAIN PUMP (1/2)
1) STRUCTURE
953 535 789 732 532 214 548 531 724 702 792 534 808 901 954 719 151 152 211 113
808 A
886
717
406
261
04
774
111
127
123
710
824
251 490 212 153 156 468 157 885 314 981 012 271 401
728 313 124 312 114 466 983
725
33092MP02A
04 Gear pump 271 Pump casing 719 O-ring

111 Drive shaft (F) 312 Valve block 724 O-ring
113 Drive shaft (R) 313 Valve plate (R) 725 O-ring
114 Gear 314 Valve plate (L) 728 O-ring
123 Roller bearing 401 Hexagon socket bolt 732 O-ring
124 Needle bearing 406 Hexagon socket bolt 774 Oil seal
127 Bearing spacer 466 VP plug 789 Back up ring
151 Piston 468 VP plug 792 Back up ring
152 Shoe 490 VP plug 808 Hexagon head nut
153 Set plate 531 Tilting pin 824 Snap ring
156 Bushing 532 Servo piston 885 Pin
157 Cylinder spring 534 Stopper (L) 886 Spring pin
211 Shoe plate 535 Stopper (S) 901 Eye bolt
212 Swash plate 548 Pin 953 Set screw
214 Bushing 702 O-ring 954 Set screw
251 Swash plate support 710 O-ring 981 Name plate
261 Seal cover (F) 717 O-ring 983 Pin
8-9
MAIN PUMP (2/2)
544
545
541
543
079
VIEW A
32092MP03
079 Proportional reducing valve 543 Stopper 1 545 Steel ball

541 Seat 544 Stopper 2
8-10
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size Part name
Allen wrench Hexagon socket PT plug PO plug Hexagon socket

B
head bolt (PT thread) (PF thread) head setscrew
4 M 5 BP-1/16 - M 8
5 M 6 BP1/ 8 - M10
B 6 M 8 BP-1/ 4 PO-1/4 M12, M14
8 M10 BP-3/ 8 PO-3/8 M16, M18
17 M20, M22 BP-1 PO-1, 1 1/4, 1 1/2 -
Double ring spanner, VP plug

- Hexagon head bolt Hexagon head bolt (PF thread)
socket wrench, double
(single) open end spanner 19 M12 M12 VP-1/4
24 M16 M16 -
B
27 M18 M18 VP-1/2
30 M20 M20 -
36 - - VP-3/4
Adjustable angle wrench Medium size, 1 set
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar Steel bar of key material approx. 10×8×200
Torque wrench Capable of tightening with the specified torques
8-11
(2) Tightening torque
Torque Wrench size
Part name Bolt size
kgf·m lbf·ft in mm
Hexagon socket head bolt M 5 0.7 5.1 0.16 4
(material : SCM435)
M 6 1.2 8.7 0.20 5
M 8 3.0 21.7 0.24 6
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.0 115.7 0.47 12
M16 24.0 173.6 0.55 14
M18 34.0 245.9 0.55 14
M20 44.0 318.3 0.67 17
PT plug (material : S45C) PT 1/16 0.7 5.1 0.16 4
※ Wind a seal tape 1 1/2 to
PT 1/ 8 1.05 7.59 0.20 5
2 turns round the plug
PT 1/ 4 1.75 12.66 0.24 6
PT 3/ 8 3.5 25.3 0.31 8
PT 1/ 2 5.0 36.2 0.39 10
PF plug (material : S45C) PF 1/ 4 3.0 21.7 0.24 6
PF 1/ 2 10.0 72.3 0.39 10
PF 3/ 4 15.0 108.5 0.55 14
PF 1 19.0 137.4 0.67 17
PF 1 1/4 27.0 195.3 0.67 17
PF 1 1/2 28.0 202.5 0.67 17
8-12
3) DISASSEMBLY
(1) Select place suitable to disassembling.
※ Select clean place.
※ Spread rubber sheet, cloth or so on, on
overhaul workbench top to prevent parts
from being damaged.
(2) Remove dust, rust, etc, from pump
surfaces with cleaning oil or so on.
(3) Remove drain port plug (468) and let oil
out of pump casing. (front and rear pump).
(4) Remove hexagon socket head bolts (412,

413) and remove regulator.
Remove hexagon socket head bolts (416)
and remove gear pump.
MP01
(5) Loosen hexagon socket head bolts (401)

fixing swash plate support (251), pump
casing (271) and valve block (312).
(6) Place pump horizontally on workbench

with its regulator-fitting surface down,
and separate pump casing (271) from
valve block (312).
※ Before bringing this surface down, spread
rubber sheet on workbench without failing
to prevent this surface from being
damaged.
MP02
8-13
(7) Pull cylinder (141) out of pump casing
(271) straightly over drive shaft (111).
Pull out also pistons (151), set plate
(153), spherical bush (156) and cylinder
springs (157) simultaneously.
※ Take care not to damage sliding
surfaces of cylinder, spherical bushing,
shoes, swash plate, etc.
MP03
(8) Remove hexagon socket head bolts (406)

and then seal cover (F) (261).
Fit bolt into pulling out tapped hole of seal
cover (F), and cover can be removed
easily.
※ Since oil seal is fitted on seal cover (F),
take care not to damage it when removing
cover.
(9) Remove hexagon socket head bolts (408) MP04
and then seal cover (R, 262).
In case of fitting a gear pump, first,
remove gear pump.
(10) Tapping lightly fitting flange section of
swash plate support (251) on its pump
casing side, separate swash plate support
from pump casing.
MP05
(11) Remove shoe plate (211)and swash plate

(212) from pump casing (271).
MP06
8-14
(12) Tapping lightly shaft's end of drive shafts
(111, 113) with plastic hammer, take out
drive shafts from swash plate supports.
MP07
(13) Remove valve plates (313, 314) from

valve block (312).
※ These may be removed in work 6.
MP08
(14) If necessary, remove stopper (L, 534),

stopper (S, 535), servo piston (532) and
tilting pin(531) from pump casing (271),
and needle bearing (124) and gear (116)
from valve block (312).
※ In removing tilting pin, use a protector to
prevent pin head from being damaged.
※ Since loctite is applied to fitting areas of
tilting pin and servo piston, take care not
to damage servo piston.
※ Do not remove needle bearing as far as
possible, except when it is considered to
be out of its life span.
※ Do not loosen hexagon nuts of valve block
and swash plate support.
Once loosened, flow setting will be
changed.
8-15
4) ASSEMBLY
(1) F o r r e a s s e m b l i n g r e v e r s e t h e
disassembling procedures, paying
attention to the following items.
① Do not fail to repair the parts damaged
during disassembling, and prepare
replacement parts in advance.
② Clean each part fully with cleaning oil
and dry it with compressed air.
③ Do not fail to apply clean working oil to
sliding sections, bearings, etc. before
assembling them.
④ In principle, replace seal parts, such as
O-rings, oil seals, etc.
⑤ For fitting bolts, plug, etc., prepare a
torque wrench or so on, and tighten them
with torques shown in Section 2-3.
⑥ For the double-pump, take care not to
mix up parts of the front pump with those
of the rear pump.
(2) Fit swash plate support (251) to pump

casing (271), tapping the former lightly
with a hammer.
※ After servo piston, tilting pin, stopper (L)
and stopper (S) are removed, fit them
soon to pump casing in advance for
※ reassembling.
In tightening servo piston and tilting pin,
use a protector to prevent tilting pin head
MP09
and feedback pin from being damaged.
In addition, apply lock-tight (medium
strength) to their threaded sections.
8-16
(3) Place pump casing with its regulator fitting
surface down, fit tilting bush of swash
plate to tilting pin (531), and fit swash
plate (212) to swash plate support (251)
correctly.
※ Confirm with fingers of both hands that
swash plate can be removed smoothly.
※ Apply grease to sliding sections of swash
plate and swash plate support, and drive
MP10
shaft can be fitted easily.
(4) To swash plate support (251), fit drive

shaft (111) set with bearing (123), bearing
spacer (127) and snap ring (824).
※ Do not tap drive shaft with hammer or so
on.
※ Assemble them into support, tapping
outer race of bearing lightly with plastic
※ hammer.
Fit them fully, using steel bar or so on.
MP11
(5) Assemble seal cover (F, 261) to pump

casing (271) and fix it with hexagon
socket head bolts (406).
※ Apply grease lightly to oil seal in seal
cover (F).
※ Assemble oil seal, taking full care not to
damage it.
※ For tandem type pump, fit rear cover (263)
and seal cover (262).
MP12
(6) Assemble piston cylinder subassembly

〔Cylinder (141), piston subassembly
(151, 152), set plate (153), spherical bush
(156), spacer (158) and cylinder spring
(157).〕
Fit spline phases of retainer and cylinder.
Then, insert piston cylinder subassembly
into pump casing.
MP13
8-17
(7) Fit valve plate (313) to valve block (312),
entering pin into pin hole.
※ Take care not to mistake suction / delivery
directions of valve plate.
MP14
(8) Fit valve block (312) to pump casing

(271) and tighten hexagon socket head
bolts (401).
※ At first assemble this at rear pump side,
and this work will be easy.
※ Take care not to mistake direction of valve
block.
MP16
※ Clockwise rotation (viewed from input

shaft side)
※ Fit block with regulator up and with
delivery flange left, viewed from front side.
(9) Putting feedback pin of tilting pin into

feedback lever of regulator, fit regulator
and tighten hexagon socket head bolts
(412, 413).
※ Take care not to mistake regulator of front
pump for that of rear pump.
MP17
(10) Fit drain port plug (468).

T h i s i s t h e e n d o f r e a s s e m bl i n g
procedures.
8-18
3. REGULATOR
1) STRUCTURE
STRUCTURE(1/2)
412 876 874 A

755
A 858
897 B P2
614
612 Pf
Pi
615
613
A 875
B 611
B
A Delivery port 1"

B Suction port 3"
Pi Pilot port PF 1/4-15
Pf Power shift pressure -
P2 Companion delivery pressure -
438
801
924
730 643 708 644 645 646 728
SECTION B-B
413 438
438
656
735 Pi
722
496 724 725 436
VIEW C 32092MP04
8-19
REGULATOR (2/2)
SECTION A-A
29092MP04A
412 Hexagon socket screw 630 Lock nut 733 O-ring

413 Hexagon socket screw 631 Sleeve, pf 734 O-ring
436 Hexagon socket screw 641 Pilot cover 735 O-ring
438 Hexagon socket screw 643 Pilot piston 753 O-ring
496 Plug 644 Spring seat (Q) 755 O-ring
601 Casing 645 Adjust stem (Q) 756 O-ring
611 Feed back lever 646 Pilot spring 763 O-ring
612 Lever (1) 651 Sleeve 801 Nut
613 Lever (2) 652 Spool 802 Nut
614 Fulcrum plug 653 Spring seat 814 Snap ring
615 Adjust plug 654 Return spring 836 Snap ring
621 Compensator piston 655 Set spring 858 Snap ring
622 Piston case 656 Block cover 874 Pin
623 Compensator rod 708 O-ring 875 Pin
624 Spring seat (C) 722 O-ring 876 Pin
625 Outer spring 724 O-ring 887 Pin
626 Inner spring 725 O-ring 897 Pin
627 Adjust stem (C) 728 O-ring 898 Pin
628 Adjust screw (C) 730 O-ring 924 Set screw
629 Cover (C) 732 O-ring
8-20
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size Part name
Hexagon socket PT plug PO plug Hexagon socket
Allen wrench B (PT thread) (PF thread)
head bolt head setscrew
4 M 5 BP-1/16 - M 8
B
5 M 6 BP1/ 8 - M10
6 M 8 BP-1/ 4 PO-1/4 M12, M14
Socket wrench, VP plug

double (single) open end - Hexagon head bolt Hexagon nut (PF thread)
B
6 M8 M8 -
Adjustable angle wrench Small size, Max 36 mm
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar Steel bar of key material approx. 10×8×200
Torque wrench Capable of tightening with the specified torques.
Pincers -
Bolt M4, Length : 50 mm
8-21
Torque Wrench size
Part name Bolt size
kgf·m lbf·ft in mm
Hexagon socket head bolt M 5 0.7 5.1 0.16 4
(material : SCM435) M 6 1.2 8.7 0.20 5
M 8 3.0 21.7 0.24 6
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.0 115.7 0.47 12
PT plug (material : S45C) PT 1/16 0.7 5.1 0.16 4
※ Wind a seal tape 1 1/2 to PT 1/ 8 1.05 7.59 0.20 5
2 turns round the plug
PT 1/ 4 1.75 12.66 0.24 6
PF plug (material : S45C) PT 1/ 4 3.0 21.7 0.24 6
8-22
3) DISASSEMBLY
Since the regulator consists of small
precision finished parts, disassembly and
assembly are rather complicated.
For this reason, replacement of a regulator
assembly is not recommended, unless there
is a special reason, but in case disassembly
is necessary for an unavoidable reason,
read through this manual to the end before
starting disassembly.
(1) Choose a place for disassembly.
※ Choose a clean place.
※ Spread rubber sheet, cloth, or so on on
top of work-bench to prevent parts from
being damaged.
(2) Remove dust, rust, etc. from surfaces of
regulator with clean oil.
(3) Remove hexagon socket head screw

(412, 413) and remove regulator main
body from pump main body.
※ Take care not to lose O-ring.
REG01
(4) Remove hexagon socket head screw

(438) and remove cover (C, 629).
※ Cover (C) is fitted with adjusting screw (C,
628), adjusting stem (C, 627), lock nut
(630), hexagon nut (801) and adjusting
screw (924).
Do not loosen these screws and nuts.
If they are loosened, adjusted pressure-
flow setting will vary.
REG02
8-23
(5) A f t e r r e m o v i n g c o v e r ( C , 6 2 9 )
subassembly, take out outer spring (625),
inner spring (626) and spring seat (C,
624) from compensating section.
Then draw out adjusting stem (Q, 645),
pilot spring (646) and spring seat (644)
from pilot section.
※ Adjusting stem (Q, 645) can easily be
drawn out with M4 bolt.
REG03
(6) Remove hexagon socket head screws

(436, 438) and remove pilot cover (641).
After removing pilot cover, take out set
spring (655) from pilot section.
REG04
(7) Remove snap ring (814) and take out

spring seat (653), return spring (654) and
sleeve (651).
Sleeve (651) is fitted with snap ring (836).
※ When removing snap ring (814), return
spring (654) may pop out.
※ Take care not to lose it.
REG05
(8) Remove locking ring (858) and take out

fulcrum plug (614) and adjusting plug
(615).
※ Fulcrum plug (614) and adjusting plug
(615) can easily be taken out with M6 bolt.
REG06
8-24
REG07
(9) Remove lever (2, 613). Do not draw out

pin (875).
※ Work will be promoted by using pincers or
so on.
REG08
(10) Draw out pin (874) and remove

feedback lever (611).
※ Push out pin (874, 4 mm in dia.) from
above with slender steel bar so that it may
not interfere with lever (1, 612).
REG09
REG10
8-25
(11) Remove lever (1, 612). Do not draw out
pin (875).
(12) Draw out pilot piston (643) and spool
(652).
(13) D r a w o u t p i s t o n c a s e ( 6 2 2 ) ,
compensating piston (621) and
compensating rod (623).
※ Piston case (622) can be taken out by
pushing compensating rod (623) at
opposite side of piston case.
This completes operation.
8-26
4) ASSEMBLY
(1) For assembly, reverse disassembly
procedures, but pay attention to the
following items.
① Always repair parts that were scored at
disassembly.
Get replacement parts ready beforehand.
② Mixing of foreign matter will cause
malfunction.
Therefore, wash parts well with cleaning
oil, let them dry with jet air and handle
them in clean place.
③ Always tighten bolts, plugs, etc. to their
specified torques.
④ Do not fail to coat sliding surfaces with
clean hydraulic oil before assembly.
⑤ Replace seals such as O-ring with new
ones as a rule.
(2) P u t c o m p e n s a t i n g r o d ( 6 2 3 ) i n t o
compensating hole of casing (601).
(3) Put pin force-fitted in lever (1, 612) into
groove of compensating rod and fit lever
(1) to pin force-fitted in casing.
(4) Fit spool (652) and sleeve (651) into hole

in spool of casing.
※ Confirm that spool and sleeve slide
smoothly in casing without binding.
※ Pay attention to orientation of spool.
Spool
Feedback lever
8-26
8-27
(5) Fit feedback lever (611), matching its pin
hole with pin hole in spool.
Then insert pin (874).
※ Insert pin in feedback lever a little to ease
operation. Lever 1 side Lever 2 side
※ Take care not to mistake direction of (adjust plug fulcrum
feedback lever. plug side)
8-27
(6) Put pilot piston (643) into pilot hole of

casing.
※ Confirm that pilot piston slides smoothly
without binding.
(7) Put pin force-fitted in lever (2, 613) into
groove of pilot piston.
Then fix lever (2).
REG11
(8) Fit fulcrum plug (614) so that pin force-

fitted in fulcrum plug(614) can be put into
pin hole of lever (2).
Then fix locking ring (858).
(9) Insert adjusting plug (615) and fit locking
ring.
※ Take care not to mistake inserting holes
for fulcrum plug and adjusting plug.
At this point in time move feedback lever
to confirm that it has no large play and is
REG12
free from binding.
(10) Fit return spring (654) and spring seat

(653) into spool hole and attach snap ring
(814).
REG13
8-28
(11) Fit set spring (655) to spool hole and
put compensating piston (621) and piston
case (622) into compensating hole.
Fit pilot cover (641) and tighten it with
hexagonal socket head screws (436, 438).
REG14
(12) Put spring seat (644), pilot spring (646)

and adjusting stem (Q, 645) into pilot hole.
Then fix spring seat (624), inner spring
(626) and outer spr ing (625) into
compensating hole.
※ When fitting spring seat, take care not to
mistake direction of spring seat.
REG15
(13) Install cover (C, 629) fitted with adjusting

screws (628), adjusting stem (C, 627),
lock nut (630), hexagon nut (802) and
adjusting screw (924).
Then tighten them with hexagonal socket
head screws (438).
This completes assembly.
REG16
8-29
GROUP 4 MAIN CONTROL VALVE
1. REMOVAL AND INSTALL OF MOTOR

1) REMOVAL

penetrate the skin causing serious
injury.
※ When pipes and hoses are disconnected,
(4) Remove the wirings for the pressure
sensor and so on.
(5) Remove bolts and disconnect pipe.
3309S8MCV01
(6) Disconnect pilot line hoses.

(7) Disconnect pilot piping.
(8) Sling the control valve assembly and
remove the control valve mounting bolt.
·Weight : 200 kg (441lb)
(9) Remove the control valve assembly. PaL
PbL
When removing the control valve

assembly, check that all the piping have XAa1
been disconnected.
2) INSTALL
3309S8MCV02
to removal.
(2) Bleed the air from below items.
① Cylinder (boom, arm, bucket)
② Swing motor
③ Travel motor
※ See each item removal and install.
(3) Confirm the hydraulic oil level and
recheck the hydraulic oil leak or not.
3309S8MCV03
8-30
2. STRUCTURE (1/4)
154
164
201
DETAIL A DETAIL B 201
201
336 336 201
201
332 332 273
322 320
A
323 321 A
B
335 335 B HOUSING-P2
(ITEM 101)
332
A
332
261 261
158
512
252 522
562
601 55
602 511
521
561
551
RH
REAR
561
153
101 513
523
514 561
521 159 552
561
51
256 LH
561
153 251
FRONT 32098MC01
101 P2 housing (casing A) 273 Socket screw 514 Poppet

153 Plug 320 Spring 521 Spring
159 Plug 323 Spring 551 Plug
164 O-ring 332 Seat 552 Plug
201 Spring cover 335 Stopper 553 Plug
251 Logic control valve 336 Bolt 561 O-ring
252 Selector lock valve 511 Poppet 562 O-ring
256 Logic poppet 512 Poppet 601 Main relief valve
261 O-ring 513 Poppet 602 Port relief valve
8-31
STRUCTURE (2/4)
P2 HOUSING 159
168
151
156
159
541
543
542
166
550
158
308 602
301
303
304 264
264
306 264
204
264 204 164
264 208 154
204 168
260
206
273
211
561
258
32098MC02
151 Plug 206 Cover 304 Bucket spool

154 Plug 208 Cover-spool 306 Arm 2 spool
156 Orifice 211 Piston 308 Straight travel spool
158 Plug 258 Plug 541 Steel ball
159 Plug 260 Plug 542 Spring seat
164 O-ring 264 O-ring 543 Spring
166 O-ring 273 Socket screw 550 Plug
168 O-ring 301 Travel, LH spool 561 O-ring
204 Cover 303 Boom 1 spool 602 Port relief valve
8-32
STRUCTURE (3/4)
152 259 DETAIL A DETAIL B

257 162 164
603 336 336
610 201
152 202 332 332
162
203 322 326
273 A
C
B 323 327
102
C
C REAR 335 339
D
RH
332 332
154
164 261 261
161
165 DETAIL C DETAIL D
165
163 336 333
210 332 331

167 163 165
155
320 370
274 165 161 LH
165 163 165
FRONT 321 371
250 978
977 153
971 254 561 335 337
209 E 332 331
165 E
154 261 262
164 G
158
E F
E 551
975 561
521 E
511
P1 HOUSING
(ITEM 102)
551 F 152162 G
561
32098MC03
102 P1 housing (casing B) 201 Spring cover 274 Socket screw 337 Stopper
152 Plug 202 Spring cover 320 Spring 339 Stopper
153 Plug 203 Spring cover 321 Spring 370 Spring
154 Plug 209 Flange 322 Spring 371 Spring
155 Plug 210 Plate 323 Spring 511 Poppet
158 Plug 250 Logic control valve 326 Spring 521 Spring
161 O-ring 254 Logic poppet 327 Spring 551 Plug
162 O-ring 257 Arm regen cut sub 331 Seat 561 O-ring
163 O-ring 259 Plug 332 Seat 603 Port relief valve
164 O-ring 261 O-ring 333 Spacer bolt 610 Nega control relief valve
165 O-ring 262 O-ring 335 Stopper 971 Screw
167 O-ring 273 Socket screw 336 Bolt 975 Socket screw
8-33
STRUCTURE(4/4)
STRUCTURE
P1 HOUSING
604
602
DETAIL A DETAIL B
610
611 262 261
331 332
301
307
370 320
305
310 371 329

309 264
311
302 264 337 339
313 204 331 332

264
B 204 333 336
264
A 204
203
164 202
205
154
273
21098MC07
154 Plug 302 Arm 1 spool 333 Spacer bolt

164 O-ring 305 Swing spool 336 Bolt
202 Spring cover 307 Boom 2 spool 337 Stopper
203 Spring cover 309 Option spool 339 Stopper
204 Cover 310 Bypass cut spool 370 Spring
205 Cover 311 Swing priority spool 371 Spring
261 O-ring 313 Bypass cut spool 602 Port relief valve
262 O-ring 320 Spring 604 Port relief valve assembly
264 O-ring 329 Spring 610 Nega control relief valve
273 Socket screw 331 Seat
301 Travel, LH spool 332 Seat
8-34
3. DISASSEMBLY AND ASSEMBLY
1) GENERAL PRECAUTIONS
(1) All hydraulic components must be worked with precision working. Then, before disassembling and
assembling them, it is essential to select an especially-clean place.
(2) In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it.
(3) When a control valve is to be remove from the machine, apply caps and masking seals to all
ports. Before disassembling the valve, recheck that these caps and masking seals are fitted
completely, and then clean the outside of the assembly. Use a proper bench for working, spread
a paper or rubber mat on the bench, and disassemble the valve on it.
(4) Support the body section carefully when carrying, transferring and so on of the control valve. Do
not support the lever, exposed spool, end cover section or so on without fail.
(5) After disassembling and assembling of the component, it is desired to carry out various tests (for
the relief characteristics, leakage, flow resistance, etc.), but the hydraulic test equipment is
necessary to these tests. Therefore, even when its disassembling can be carried out technically,
do not disassemble such components that cannot be tested, adjusted, and so on. Besides,
prepare clean cleaning oil, hydraulic oil, grease, etc. beforehand.
2) TOOLS
Before disassembling the control valve, prepare the following tools beforehand.
Name of tool Quantity Size (mm)

Vice mounted on bench (soft jaws) 1 unit
Box wrench Each 1 piece 24, 32, 36
Hexagon key wrench Each 1 piece 4, 5, 6, 8, 10 and 12
Loctite #262 1 piece -
32 (main relief valve, 601)
Spanner Each 1 piece
36 (port relief valve, 603)
8-35
3) DISASSEMBLY
The figure in ( ) shown after the part name
in the explanation sentence shows its
number in the structure figures (8-31~34).
(1) Place control valve on working bench.
ö Disassemble it in clean place and pay
attention not to damage flange faces and
plate faces.
21098MC37
(2) Disassembling of main spools

· Travel (301), bucket (304), swing (305),
option (308), arm 2 (306), boom 2 (307),
swing priority (311).
Η Loosen the hexagon the socket head bolts
(273) and remove the spring cover (201,
202) and the O-ring (261).
ÂHexagon key wrench : 6 mm
21098MC38
Θ Pull out the spool, spring, spring seats

(322), stopper (335 or 339) and spacer
bolt (336) in the spool assembly condition
from the casing.
ö When pulling out the spool assembly from
housing, pay attention not to damage the
housing.
21078MC11
8-36
Ι Hold the spool in the mouthpiece-attached
vise applying a protection plate (aluminum
plate and the like) in between. Remove the
spacer bolt (336) and disassemble the
stopper (335 or 339) and spring seats
(332).
21098MC40
(3) Disassembling of boom 1 spool (303):

Η Loosen the hexagon socket head bolts
(273), and remove the spring cover (201)
and the O-ring (261).
Θ Pull out the boom 1 spool (303), spring
(320, 321), spring seats (332), stopper
(335) and spacer bolt (336) in the spool
assembly condition from the P2 housing
(101).
P2 housing (101), pay attention not to
damage housing.
21098MC41
Ι Hold the boom1 spool (303) in the
mouthpiece-attached vise applying a
protection plate (aluminum plate and the
like) in between. Remove the spacer bolt
(336), and disassemble the spring (320,
321), spring seats (332) and stopper
(335).
Κ Do not disassemble the boom1 spool
(303) more than these conditions.
8-37
(4) Disassembling of arm 1 spool (302):
Θ Pull out the arm 1 spool (302), spring
(320, 321), spring seats (332), stopper
(335) and spacer bolt (336) in the spool
assembly condition from the P1 housing
(102).
21098MC42
P1 housing(102), pay attention not to
damage housing.
Ι Hold the ar m 1 spool (302) in the
(336), and disassemble the spring (320,
(335).
Κ Do not disassemble the arm 1 spool (302)
more than these conditions.
(5) Disassembling of travel straight spool (308):

Θ Pull out the travel straight spool (308),
spring (322, 323), spring seat (332),
stopper (335) and spacer bolt (336) in the
spool assembly condition from the P2
housing (101).
damage housing.
21098MC43
8-38
Ι Hold the travel straight spool (308) in the
(336) and disassemble the spring(322,
323), spring seats(332) and stopper (335).
Κ Do not disassemble the travel straight
spool (308) more than these conditions.
(6) Disassembling of bypass cut spool (310, 313):

Θ Pull out the bypass cut spool (310, 313),
spring (370, 371), spring seats (331),
stopper (337) and spacer bolt (333) in the
spool assembly condition from the P1
housing (102).
damage housing. 21098MC44
Ι Hold the bypass cut spool (310,313) in the

(333) and disassemble the spring (370,
(337).
21098MC45
8-39
(7) Disassembling of spool covers (204, 205, 206, 208):
Η Remove the hexagon socket head bolts
(273), and remove the spool cover (204,
205, 206, 208) and the O-ring (264).
Θ In removing the bucket spool cover (206),
at first loosen the plug (258) before it is
removed from the P1 housing (102). After
removing the bucket spring cover (206)
remove the plug (551), and take out the
piston (211).
ÂBox wrench : 32 mm
21098MC46
(8) Removal of main relief valve (601) port

relief valves (602, 603, 604) :
Η Remove the main relief valve (601) and
the port relief valves (602, 603, 604) from
the housing.
Main relief valve (601) : spanner 32mm
Port relief valve (602) : spanner or box
wrench 32mm
Port relief valve (603) : spanner 36mm
Port relief valve (604) : spanner or box
wrench 36mm 21098MC47
Θ Do not disassemble the relief valves more

than these conditions.
21098MC48
8-40
21098MC49
(9) Removal of lock valve selector (252):

(252-171) and remove the lock valve
selector (252) and the O-rings (252-161).
Θ Do not disassemble the lock valve selector
(252) more than these conditions.
21098MC50
(10) Removal of negative control relief valve

(610):
Η Remove the negative control relief valve
(610) from the P1 housing (102).
Θ Do not disassemble the negative control
relief valve (610) more than these
conditions.
21098MC51
8-41
(11) Removal of arm regeneration cut valve (257):
Remove the plug (253), spring (331),
spool (211), and sleeve (392) from the P1
housing (102).
21098MC52
(12) Disassembly of logic control valve (250, 251)

and logic poppet (254, 256):
(250-120, 251-120) and remove the logic
control valve (250, 251) and the O-rings
(250-112 and 113, 251-112 and 113).
Θ Pull out the logic poppet (254, 256), spring
(254-106, 256-106) and spring seat (254-
21098MC53
103, 256-103) from the housing.
Ι Do not disassemble the logic control valve
and the logic poppet more than these
condition.
21098MC54
(13) Disassembly of check valve :

Η CP1, C2, CCb, LCb, LCo, LCk, LCa,
LCAT2
Remove the plug (551) and take out the
poppet (511) and the spring (521).
Θ CMR1, CMR2
ÂHexagon key wrench : 10 mm 21098MC55
8-42
Ι CRa, CRb
21098MC56
Κ CCk, CCo
Remove the plug (551) and take out
Λ Remove the plug (550) and take out the
ball (541), spring (543) and spring seat
(542).
21098MC57
(14) Disassembly of flanges (209) :

Loosen the hexagon socket head bolts
(971) and remove the flange (209) and the
O-ring (165).
(15) Disassembly of plate (210) :

Loosen the hexagon socket head bolts
(274) and remove the plate (210) and the
O-rings (165).
(16) Disassembly of orifices for signal line :

Do not disassemble the plug (151) and
orifice (156) unless required specifically.
8-43
(17) Disassembly of casing :
Η Except when required specially, do not
disassemble the tie bolts of the P1
housing.
Θ Since the plugs not described in above
disassembling procedures are the blind
plugs for sacrifice holes and the blind
plugs for the housing sanitation, do not
disassemble them as far as not required
specially.
21098MC58
8-44
(18) Inspection after disassembling
Clean all the disassembled parts with clean mineral oil fully, and dry them with compressed air.
Then, place them on clean papers or cloths for inspection.
Η Control valve
a. Check whole surfaces of all parts for burrs, scratches, notches and other defects.
b. Confirm that the seal groove faces of the housing and the covers are smooth and free of dust,
dent, rust etc.
c. Correct dents and damages on check seat faces of housing, if any, by lapping.
ö Pay attention not to leave lapping agent in the housing.
d. Confirm that all sliding and fitting parts can be moved manually and that all grooves and paths
are free from foreign matter.
e. If any spring is broken or deformed, replace it with new one.
f. When a relief valve does not function properly, repair it, following its inspection procedures.
g. Replace all the O-rings with new ones.
Θ Relief valve
a. Confirm that all seat faces at ends of all poppets and seats are free of defects and are uniform
contact faces.
b. Confirm manually that main poppet and seat can slide lightly and smoothly.
c. Confirm that outside face of main poppet and inside face of seat are free from scratches and so
on.
d. Confirm that orifices of the main poppet and seat section are not clogged with foreign matter.
e. Replace all O-rings with new ones.
f. When any light damage is found in above inspections, correct it by lapping.
g. When any abnormal part is found, replace it with a relief valve assembly.
8-45
4) ASSEMBLY
Η In this assembling section, explanation only is shown. Refer to figures and photographs shown in
disassembling section.
Θ Figure in ( ) shown after part name in explanation sentence shows number in structure figure.
Ι Cautions in assembling O-rings
a. Pay attention to keep O-rings free from defects in its forming and damages in its handling.
b. Apply grease, hydraulic oil or so on to O-rings and seal-fitting sections for full lubrication.
c. Do not stretch O-rings so much to deform them permanently.
d. In fitting O-ring, pay attention not to roll it into its position. In addition, twisted O-ring cannot
remove its twisting naturally with ease after being fitted, and causes oil leakage.
e. Tighten fixing the bolts for all sections with a torque wrench to their respective tightening
torque.
(1) Assembly of check valve :

Η Assemble the poppets (511, 512, 513,
514) and the springs (521, 522, 523) : Put
the O-rings (561) onto the plugs (551,
552). Put the O-rings (562) onto the plugs
(553). Tighten the plugs (551, 552, 553)
with their specified torques.
ö Use the poppets, springs and plugs in
following groups.
Poppet Spring Plug Remember that

511 521 551 511 in 8 positions
512 522 553 512 in 2 positions
21098MC57
513 523 552 513 in 2 positions
514 521 551 514 in 2 positions
Plug Hexagon key Tightening torque

No. wrench (mm) (kgf·m)
551 12 23.5 ~ 26.5
552 12 23.5 ~ 26.5
553 10 13.3 ~ 15.3
21098MC56
8-46
Θ Assemble of ball (541), spring Seat (542)
and spring (543) : Put the O-ring (166)
onto the plug (550), and tighten the plug
(550) with specified torque.
ÂTightening torque : 2.55 ~ 2.96 kgf·m
(18.4~21.4 lbf·ft)
21098MC55
(2) Assembly of plate (210) :

Fit the O-rings (165) to the P1 housing
(102), and tighten the hexagon socket
head bolts (274) with specified torque.
(72.3~88.2 lbf·ft)
So turn the control valve that the plate
face may be directed downward.
(3) Assembly of flange (209) :

Fit the O-rings (165) to the flange (209),
and tighten the hexagon socket head bolts
(36.2~47.7 lbf·ft)
(4) Assemble of logic control valve (250, 251):

Η Put the O-ring (250-115, 251-115) onto
the plug (250-111, 251-111).
21098MC53
8-47
Θ Assemble the spool (250-102, 251-102),
spring seat (250-104, 251-104) and spring
(251-105, 251-105) into the casing (250-
101, 251-101) of the logic control valve,
and tighten the plug (250-111, 251-111)
with specified torque.
(50.6~58.6 lbf·ft)
Ι Assemble the logic poppet (254; poppet,
spring, spring seat) into the housing of the 21098MC54
control valve.
Κ Fit the O-rings (250-112 and 113, 251-112
and 113) to the casing (250-101, 251-101)
of the logic control valve, and tighten the
hexagon socket head bolts (250-120, 251-
120) with specified torque.
(36.2~47.7 lbf·ft)
(5) Assembling of negative control relief

valve (610) :
Assemble the negative control relief valve
(610) into the P2 housing (101), and
tighten it with specified torque.
(50.6~57.9 lbf·ft)
21098MC51
8-48
(6) Assembly of arm regeneration cut valve
(257) :
Assemble the sleeve (257-212), spool
(257-211), and spring (257-231) into the
P1 housing (102). Put the O-ring (265)
onto the plug (257-253), and tighten with
specified torque.
(50.6~57.9 lbf·ft)
21098MC52
(7) Assembling of lock valve selector (252) :

Fit the O-rings (252-161) to the lock valve
selector (252) and tighten the hexagon
socket head bolts (252-171) with specified
torque.
(7.2~10.1 lbf·ft)
21098MC50
(8) Assembling of main relief valve (601)

and port relief valve (602, 603, 604) :
Assemble the main relief valve (601) and
the port relief valves (602, 603, 604) to the
housing, and tighten them with specified
torque.
Tightening
Item Tool
torque (kgf·m)
Main relief valve (601) Spanner 32 7.0 ~ 8.1
Spanner 32 or
Port relief valve (602) 7.0 ~ 8.1
box wrench 32
Port relief valve (603) Spanner 36 12.2 ~14.3
Spanner 36 or
Port relief valve (604) 12.2 ~14.3
box wrench 36 21098MC49
8-49
21098MC48
21098MC47
(9) Assemble of travel straight spool (308) :

Η Hold the middle of the travel straight spool
(308) in the mouthpiece-attached vise
applying a protection plate (aluminum
plate and the like) in between. Attach the
spring seats (332), springs (322, 323) and
stopper (335), and tighten the spacer bolt
※ Before tightening the spacer bolt (336),
apply loctite #262 to it.
(11.6~13.0 lbf·ft)
※ Pay attention not to fasten the vise
excessively to the shape of the travel 21098MC43
straight spool (308) is deformed.

Θ Insert the spool assemblies of Η items
above into the P2 housing (101).
※ Fit spool assemblies into P2 housing (101)
carefully and slowly.
※ Do not push them forcibly without fail.
8-50
(10) Assembling of boom 1 spool (303) :
Η Hold the middle of the boom1 spool (303)
in the mouthpiece-attached vise applying
a protection plate (aluminum plate and the
like) in between. Attach the spring seats
(332), springs (320, 321) and stopper
(335), and tighten the spacer bolt (336)
(11.6~13.0 lbf·ft)
excessively to the shape of the boom 1 21098MC41
spool (303) is deformed.

Θ Insert the spool assemblies of items Η
※ Fit spool assemblies into the P2 housing
(101) carefully and slowly.
(11) Assembling of arm 1 spool (302) :

Η Hold the middle of the arm1 spool (302) in
the mouthpiece-attached vise applying a
(335) and tighten the spacer bolt (336)
ÂHexagon key wrench : 10 mm 21098MC42

(11.6~13.0 lbf·ft)
excessively to the shape of the arm 1
spool (302) is deformed.
Θ Insert the spool assemblies of items Η
8-51
(12) Assembling of main spool (travel (301),
bucket (304), swing (305), option (309),
arm2 (306), boom2 (307), swing priority
(311)):
Η Hold the middle of each spool in the
(332), springs and stopper (335 or 339)
and tighten the spacer bolt (336) with
specified torque.
21098MC39
(11.6~13.0 lbf·ft)
excessively to the shape of the spool is
deformed.
Θ Insert the spool assemblies of Items Η
above into the P2 housing (101) and P1
housing (102).
※ Fit spool assemblies into P2 housing (101)
and P1 housing (102) carefully and slowly.
21098MC38
8-52
(13) Assembling of bypass cut spool (310, 313) :
Η Hold the middle of each spool in the
(337) and tighten the spacer bolt (333)
(11.6~13.0 lbf·ft)
excessively to the shape of the bypass cut 21098MC44
spool (310, 313) is deformed.
Θ Insert the spool assemblies of Items Η
(14) Assembling of covers :

Η Fit the O-rings (264) to the spool covers
(204, 205, 206, 208) to sides reverse to
the spring sides of spools, and tighten the
hexagon socket head bolts (273) with
specified torque.
※ Confirm that O-rings (264) have been
fitted to the spool covers (204, 205, 206,
208).
(18.1~25.3 lbf·ft)
Θ Bucket spool cover (206) : Assemble
piston (355) into bucket spool cover (206).
Put O-ring (561) onto plug (258) and
tighten it with specified torque. 21098MC46
(111~133 lbf·ft)
Ι Fit the O-rings (261, 262) to spring covers
(201, 202, 203) to the spring sides of
spools, and tighten the hexagon socket
head bolts (273) with specified torque.
※ Confirm that O-rings (261,262) have been
fitted to spring covers (204, 205, 206).
(18.1~25.3 lbf·ft)
8-53
GROUP 5 SWING DEVICE
1. REMOVAL AND INSTALL OF MOTOR

1) REMOVAL
(2) Loosen the breather slowly to release the
penetrate the skin causing serious in
13031GE18
injury.
catch it in oil pan. 2 4
(3) Disconnect pipe assy (2, 3). 3
(4) Disconnect pilot line hoses (4, 5, 6, 7, 8, 9).

(5) Sling the swing motor assembly (1)and
remove the swing motor mounting bolts 10
1
(10).
· Motor device weight : 65 kg (140 lb)
· Tightening torque : 58.4 kgf·m
3309S8SM02
(422.4lbf·ft)
(6) Remove the swing motor assembly.
※ W h e n r e m ov i n g t h e sw i n g m o t o r
6
assembly, check that all the piping have
5
been disconnected.
2) INSTALL
7
9
to removal.
(2) Bleed the air from the swing motor.
8
① Remove the air vent plug.
② Pour in hydraulic oil until it over flows 3309S8SM01
from the port.

③ Tighten plug lightly.
④ Start the engine, run at low idling, and
⑤ Tighten plug fully.
(3) Confirmed the hydraulic oil level and
check the hydraulic oil leak or not.
8-54
2. SWING MOTOR
1) STRUCTURE
121 120 117 116 142 141 119 118 140 113 236 227 123 124 125 126 235
143
137
113
139
145 A
138
144 A
114
122 133
X
136 X
102 115
130 134
129
135
103
101
104 105 106 111 108 131 109 110 107 112 132 146 127
128
236 237
SECTION A - A SECTION X-X

32092SM02
101 Casing A1 118 Brake spring 135 Ring snap

102 Drive shaft 119 Brake piston 136 Dust plug
103 Shoe plate 120 Piston 137 Ring snap
104 Shoe 121 Spacer F 138 Name plate
105 Retainer 122 Front cover 139 Rivet screw
106 Spherical bush 123 RO plug 140 O-ring
107 Brake valve 124 Spring 141 O-ring
108 Cylinder block 125 Plunger K 142 O-ring
109 Friction plate 126 S/reaction less valve 143 Ring snap
110 Separation pate 127 Relief valve 144 Roller bearing
111 Push rod 128 VP plug 145 O-ring
112 Valve plate 129 Ring snap 146 Socket bolt
113 Spacer 130 Oil seal 227 Socket bolt
114 VP plug 131 Dust plug 235 Pin
115 Valve casing 132 Pin spring 236 Level gauge
116 Cylinder spring 133 Roller bearing 237 Air breather assy
117 Spacer R 134 Dust plug
8-55
2) DISASSEMBLY
(1) Lift the motor out. Clean the motor in
kerosene and dry with compressed air.
ö To avoid dust inside the motor, mask all
the ports of the motor with tapes.
32038SM01
(2) Loosen the drain plug to discharge oil in

the casing (101).
32038SM02
(3) Fix the drive shaft (102) on the workbench

with the end of output shaft down. Put
matching marks on casing (101) and
valve casing (303) for easy reassembly.
32038SM03
(4) Remove the valve (107).
32038SM04
8-56
(5) Remove the relief valve (127) from valve
casing (115).
32038SM05
(6) Remove plug (123) from valve casing

(115) and spring (124), plunger (125).
ö Be careful not to damage the plunger seat
assembly.
32038SM06
(7) Remove valve casing (115) from casing

(101). Then, remove the valve plate (112)
from valve casing (115) with care.
32038SM07
(8) Remove the brake spring (118) from

brake piston (119).
32038SM08
8-57
(9) Remove brake piston (119) from casing
(101).
32038SM09
(10) Remove the cylinder (108) from the output

shaft (102) with the motor positioned
horizontally. Remove piston (104, 120),
retainer (105), spherical bush (106),
spacer (121) and shoe plate (103).
ö If shoe plate would not removed easily, try
again after procedure (14).
32038SM10
(11) Remove friction plate (109) and separate

plate (110) from casing (101).
32038SM11
(12) Remove snap ring (129) with pillar and

remove the front cover (122) from casing
(101).
ö Front cover could be removed with sliding
shaft if necessary.
32038SM12
8-58
(13) Remove drive shaft (102) from casing
(101).
32038SM13
(14) Remove the shoe plate (103) from casing

(101).
32038SM14
(15) Proceed with following job only when

necessary.
Η Remove the snap ring (143), spacer
(113) from drive shaft (102) and remove
the cone of roller bearing (144) by press.
ö Do not reuse bearings.
Press
32038SM15
Output shaft
Roller bearing
Θ Remove oil seal (130) from front cover

(122).
32038SM16
8-59
Ι Remove the roller bearing (133) from the
valve casing (101) by using slide
hammer bearing puller.
32038SM17
Κ When disassembling the relief valve,

release the plug (3). 3
Remove the piston (7), spring seat (9), 5
spring (8) and plunger (6) with the body 4
(1) downwards. 15
ö Do not release the lock nut (15). 11
14
7
13
9
12
2
1
10
29078SM04
This completes disassembly.
8-60
3) ASSEMBLY
Do the reassembly in the reverse procedure
of the disassembly.
(1) Place the casing (101) on the workbench
with the valve casing (115) downward.
32038SM20
(2) When reassembling the roller bearing,

install the snap ring (143), and spacer
(113) to the drive shaft (102). Insert the
collar and cone of the roller bearing (144).
Install the spacer (113) and stop ring
(143). Install stop ring (144) to the output
shaft (102) by heating the cone of the
roller bearing (133).
32038SM21
Out put
Round ring parts of

the collar toward
spacer
Spacer
32038SM22
(3) Insert the drive shaft (102) into the casing

(101) with the end of output shaft upward
and tap the outer race of roller bearing
with the hammer.
32038SM23
8-61
(4) Tack O-ring (145) to the casing (101).
32038SM25
(5) Reassemble the front cover (122) to the

casing (101).
ö Apply grease to the rib of oil seal to avoid
damage to the rib.
32038SM26
(6) Install the snap ring (129) to the casing

(101).
32038SM27
(7) Insert the shoe plate (103) with the casing

(101) position horizontally.
32038SM28
8-62
(8) Insert the spherical bush (106) into the
cylinder (108). Place the retainer (105)
assembled with spacer (121) onto the
cylinder.
ö Insert two push rods in each hole.
32038SM29
(9) Install the piston sub-assembly (120, 104)

to the retainer (105).
32038SM30
(10) Reassemble the piston assembly (120,

104) to the cylinder block (108).
32038SM31
(11) Place the casing (101) under the front

cover (122) and reassemble 3 sheets of
separate plate (110) and then 2 sheets of
friction plate (109) to the casing (101).
32038SM32
8-63
(12) Insert O-ring (141, 142) inside the casing
(101).
32038SM33
(13) Reassemble brake piston (119) to the

casing (101).
32038SM34
(14) Reassemble brake spring (118) to the

brake piston (119).
32038SM35
(15) When assembling the roller bearing (133),

insert the roller bearing (444) into valve
casing (115) by hammering.
32038SM36
8-64
(16) Reassemble valve plate (112) to the valve
casing (115) and reassemble O-ring
(140).
32038SM37
(17) Connect the valve casing (115) with the

casing (101) and tighten the socket bolt
(146).
32038SM38
(18) Insert plunger (125) and spring (124) in

the valve casing. Tighten plug (123) to the
valve casing.
32038SM39
(19) Insert O-rings (127-1) to the relief valve

(127) and reassemble them to valve
casing (101).
32038SM42
8-65
(20) Tighten the plug (114) to valve casing
(115) to casing (301).
32038SM43
(21) Connect the valve casing (115) with the

casing (101).
This completes assembly.
8-66
3. REMOVAL AND INSTALL OF REDUCTION GEAR
1) REMOVAL
(1) Remove the swing motor assembly.
For details, see removal of swing motor
assembly.
(2) Sling reduction gear assembly(1) and
remove mounting bolts(2).
(3) Remove the reduction gear assembly.
ÂReduction gear device weight : 320 kg
13031GE18
(705 lb)
2) INSTALL
to removal.
Â Mounting bolt : 84Ü8.0 kgfÂm
(608Ü58 lbfÂft) 1
29098SR00
8-67
4. REDUCTION GEAR
1) STRUCTURE
233 234
220 218 228 221 232 230 204 222 206 205 207 210 226 209 225
223
A
231
229
202
216
219 214 201 224 203 211 215 213 217 208 212
32092RG01
201 Casing 212 Sun gear 1 223 Socket bolt

202 Pinion shaft 213 Ring gear 224 Hex bolt
203 Preload plate 214 Cover 225 Needle bearing
204 Carrier 2 215 Thrust washer 226 Inner ring
205 Planet gear 2 216 Thrust plate 228 PT plug
206 Pin 217 Thrust washer 229 Snap ring
207 Bush 218 Oil seal 230 Magnet
208 Carrier 1 219 Socket bolt 231 Flat head screw
209 Planet gear 1 220 Spherical roller bearing 232 Connector (1/2 inch)
210 Thrust washer 221 Cylindrical roller bearing 233 Hose assembly
211 Sun gear 2 222 Spring pin 234 Drain valve assembly
8-68
2) DISASSEMBLY
234
(1) Remove connector (232), hose assy (233) 233
and drain valve (234).
232
32098SR02
(2) Remove gauge bar(236) and gauge pipe

(237) from the swing motor casing.
Pour the gear oil out of reduction gear into
the clean bow1 to check out the friction
decrease.
236
237
32098SR03
(3) Loosen the socket bolt (223) to separate

swing motor from reduction gear.
223
32098SR04
(4) Full out No.1 sun gear (212).

212
32098SR05
8-69
(5) Full out No.1 carrier subassembly.
No.1 Carrier
subassembly
32098SR06
(6) Full out No.2 sun gear (211).

※ Pay attention to ensure gear is not
damaged during disassembling. 211
32098SR07
(7) Loosen the hexagon bolt (224).

224
32098SR08
(8) Full out No.2 carrier subassembly.
No.2 Carrier
subassembly
32098SR09A
8-70
(9) Loosen the hexagon socket bolt (227).
227
32098SR10
(10) Tighten two M10 eye bolts to ring gear

(213) and lift up and remove ring gear
(213).
213
32098SR11
(11) Full out pin (235).

235
32098SR12
(12) Full out magnet (230).

230
32098SR13
8-71
(13) Loosen the hexagon socket bolt (219).
219
32098SR14
(14) Remove the shaft sub assembly with

pinion shaft (202).
Shaft sub
assambly
219
32098SR15
(15) Press drive shaft by using jig to remove

spherical roller bearing (220) and cover
220
(214).
214
32098SR16
(16) Full out oil gear (218).

218
32098SR17
8-72
2) ASSEMBLY
(1) Place the casing (201) on the reversing
machine having the flange sid of the
casedown.
201
32098SR18
(2) Press the insert oil seal (218) by using

pressure jig after spreading grease oil
218
around the out side ring of the seal.
Coat grease oil slightly on the lip surface
to prevent any scratch when installing.
※ Be sure to check by eye that the oil seal is
seated completely after being installed.
32098SR17
(3) Insert cover (214) to pinion shaft (202)

and insert spherical roller bearing (220)
220
by using a pressing jig.
214
32098SR16
(4) Install pinion shaft (202) sub assembly

into casing by using a pressing jig.
201
202
32098SR19
8-73
(5) Install roller bearing (221) into casing by
using a pressing jig.
221
201
32098SR20
(6) Insert magnet (230).

230
32098SR13
(7) Insert pin (235).

235
32098SR12
(8) Place ring gear on the case by matching it

with pin hole.
※ Be sure to check the hole location of oil
gage before inserting. 213
32098SR11
8-74
(9) Assemble ring gear with case by screwing
socket bolt (227). 227
32098SR10
(10) Mount No.2 carrier subassembly in the

casing.
No.2 Carrier
subassembly
32098SR09A
(11) Tighten hexagon bolt (224).

224
32098SR08
(12) Install No.2 sun gear (211).
211
32098SR07
8-75
(13) Mount No.1 carrier subassembly.
No.1 Carrier
subassembly
32098SR06
(14) Install No.1 sun gear (212).

212
32098SR05
(15) Tighten socket bolt (223) around the

swing motor assembly.
223
32098SR04
(16) Assemble gauge bar (236) and gauge

pipe (237).
236
237
32098SR03
8-76
(17) Assemble connector (232).
Hose assy (233) and drain valve (234). 234
233
232
32098SR02
8-77
GROUP 6 TRAVEL DEVICE

1) REMOVAL
(1) Swing the work equipment 90。and lower
it completely to the ground.

injury. 1
※ When pipes and hoses are disconnected, 2
(4) Remove the track shoe assembly.
For details, see removal of track shoe
assembly.
3309S8TM01
(5) Remove the cover.

(6) Remove the hose.
※ Fit blind plugs to the disconnected hoses.
(7) Remove the bolts and the sprocket.
(8) Sling travel device assembly (1).
(9) Remove the mounting bolts (2), then
remove the travel device assembly.
2) INSTALL
to removal.
(2) Bleed the air from the travel motor.
① Remove the air vent plug.
② Pour in hydraulic oil until it overflows from
the port.
③ Tighten plug lightly.
④ Start the engine, run at low idling, and
⑤ Tighten plug fully.
(3) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.
8-78
2. TRAVEL MOTOR
1) STRUCTURE
89-5 89-4 89-3 89-2 89-6 88-6 88-4 88-2 93 88-3 88-5 86 85 87 83 13 14 15 16 25 24 6 28 30 31 4 40 39 43 38 37 71 42 41 47 50
29
89-6
35
90-2
32
90-3
90-4 33
A
97 27
92 21
90-5 49
98
48
100
36
11
103 46
73 34
74 44
12
45
91
96
56
89-8 67
89-7
62
90-1
99 A
88-8
63
89-1
65
88-7 105 95 94 88-1 5 72 9 8 7 10 84 23 22 82 17 18 19 1 20 26 3 69 2 68 61 64 60 66 57 58,59 70 55 54 53 52 51
SECTION A-A
32092TM01
1 Casing 16 Plate 31 Ring 46 Back up ring 61 O-ring 83 Housing 89-1 Carrier No.2 92 Plug
2 Plug 17 Piston 32 Spring 47 Cap 62 Lock screw 84 Bearing 89-2 Planetary gear No.2 93 Lock pin
3 Screw 18 Stopper 33 Valve casing 48 Cap 63 Nut 85 Shim 89-3 Needle No.2 94 Ring gear
4 Screw 19 O-ring 34 Needle bearing 49 Socket bolt 64 Spool 86 Retainer 89-4 Thrust washer No.2 95 Bolt
5 Pin 20 Back up ring 35 O-ring 50 Socket bolt 65 Plug 87 Bolt 89-5 Pin No.2 96 Thrust ring No.1
6 Pin 21 Cylinder block 36 Pin 51 Seat 66 O-ring 88 Carrier No.3 89-6 Spring pin No.2 97 Cover
7 Stopper 22 Cylinder spring 37 Spool 52 Steel ball 67 Valve plate 88-1 Carrier No.3 89-7 Sun gear No.2 98 Thrust ring No.2
8 O-ring 23 Spacer 38 Screw 53 Stopper 68 Spring 88-2 Planetary gear No.3 89-8 Snap ring No.2 99 Bolt
9 Back up ring 24 Guide 39 Damping check 54 Plug 69 O-ring 88-3 Needle No.3 90 Carrier No.1 100 Motor ring
10 Piston 25 Plate 40 Spring 55 O-ring 70 Socket bolt 88-4 Thrust washer No.3 90-1 Carrier No.1 101 Thrust ring No.3
11 Shaft 26 Piston & Shoe assy 41 O-ring 56 Plug 71 Socket bolt 88-5 Pin No.3 90-2 Planetary gear No.1 103 Pad
12 Spacer 27 Plate 42 Plunger 57 Relief valve 72 Lock screw 88-6 Spring pin No.3 90-3 Needle bearing No.1 105 Coupling
13 Roller bearing 28 Plate 43 Spring 58 O-ring 73 Oil seal 88-7 Sun gear No.3 90-4 Thrust washer No.1
14 Stop ring 29 Brake 44 Stopper 59 Back up ring 74 Lock ring 88-8 Snap ring No.3 90-5 Pin No.1
15 Support 30 Ring 45 O-ring 60 Rod 82 Floating Seal 89 Carrier No.2 91 Sun gear No.1
2-<#>
8-79
2) TOOL AND TIGHTENING TORQUE
(1) Tools
Name of tools B-size Name of part applied

4 Plug(2), Orifice screw(3, 4, 38)
Hexagonal 8 Hex socket bolt(50), Lock screw(62, 72), Plug(65)

L-Wrench 10 Hex socket bolt(49)
46 Hex(57)
19 Hp plug(54)
Socket wrench/
24 Hex nut(63)
spanner
27 Hp plug(56)
Snap-ring plier(for holes, axis) Ring stop(14), Ring lock(74)
Solder hammer Needle bearing(34), Pin(5, 6, 36)
Torque wrench Size : 500, 3000
Jig for assembling oil seal Oil seal(73)

Torque
NO. Part name Standard Size
kgfÂm lbfÂft
2 Plug NPTF 1/16 4 7~11 50.63~79.5
3, 4, 38 Orifice screw NPTF 1/16 4 7 50.63
49 Hex socket bolt M12 10 100 723.3
50 Hex socket bolt M10 8 67 484.6
54 Plug PF 1/4 19 37 267.6
56 Plug PF 1/2 27 110 795.6
57 Relief valve HEX 46 46 170~190 1230~1374
63 Nut M16 24 240 1736
65 Plug PF 3/8 8 75 542.4
70, 72 Hex socket bolt M16 14 240 1736
71 Hex socket bolt M16 14 240 1736
8-80
2. DISASSEMBLING
1) GENERAL INSTRUCTIONS
(1) Generally, hydraulic equipment is precisely manufactured and clearances between each parts are
very narrow. Therefore, disassembling and assembling works should be performed on the clean
place where dusts hardly gather. Tools and kerosene to wash parts should also be clean and
handled with great care.
(2) When motor is removed from the host machine, wash around the ports sufficiently and put the
plugs so that no dust and/or water may invade. Take off these plugs just before the piping works
when re-attach it to the host machine.
(3) Before disassembling, review the sectional drawing and prepare the required parts, depending on
the purpose and the range of disassembling.
Seals, O-rings, etc., if once disassembled, are not reusable.
There are some parts that should be replaced as a subassembly.
Consult with the parts manual in advance.
(4) The piston can be inserted to whichever cylinder block for the initial assembling.
However, their combination should not be changed if they are once used. To reuse them, put the
matching mark on both pistons and cylinder block before disassembling.
Take great care not to pinch your hand between parts while disassembling nor let fall parts on
your foot while lifting them.
8-81
2) DISASSEMBLEING TRAVEL MOTOR
(1) Fix a hydraulic motor on jig with four

pieces of bolts (M16Ý60L).
ö When rotating jig up to 90˚in disassembling
and assembling, fix a motor making drain
plug (56) faced to the bottom.
300072TM20
(2) After disassembling drain plug (56), let an

oil in a case of a motor discharged.
ö Check whether manufactured chips or
metal dust are added in a drain oil.
300072TM21 300072TM21A
(3) In order to making the out-put axis of a

hydraulic motor faced upward,
disassemble ring lock (74) with a plier
after rotating jig up to 90˚ in disassembling
and assembling.
300072TM22
(4) Disassemble hexgon socket bolts (70, 71)

holding valve casing.
300072TM23
8-82
(5) After detaching valve casing sub,
disassemble valve plate (67).
ö In case of serious abrasion of valve plate,
exchange it to a new one.
300072TM24A 300072TM24
(6) After taking brake spring (32) and then

bonding two pieces of M16 bolts to brake
piston (29), disassemble it pulling it
upward.
ö There are 10 pieces of brake spring.
300072TM25
300072TM25A
300072TM25B
(7) First, rotate jig in disassembling and

assembling up to 90˚ then let a motor
faced toward the horizon. then disassemble
a cylinder and piston sub.a
300072TM26
(8) Disassemble stopper L (18) and piston

swash (17).
ö Piston swash : Use M5 bolt
300072TM27
8-83
(9) Disassemble swash plate (16).
300072TM28
(10) A f t e r p u t M 1 2 i n t o s u p p o r t ( 1 5 ) ,
disassemble support.
300072TM29
(11) Disassemble piston swash (10) and

stopper (7).
300072TM30
(12) In order to making the turning axis (11)

faced upward, put it way from shaft casing
tapping the bottom of the turning axis with
hammer, after rotating jig up to 90˚ in
disassembling and assembling.
ö Try to deal with roller bearing (13) without
any damage.
300072TM31
8-84
(13) Disassemble valve casing sub.
ö Try to deal with needle bearing (3) without
any damage.
Η D i s a s s e m bl e p l ow i n g r o a d ( 6 0 ) ,
automatic changeover spring (68), and
automatic changeover spool (64).
ö Do not touch hexagon nut (63) for
controlling the amount of an oil and lock
300072TM32
screw (62). 300072TM32A
If there is any abnormality on plowing 300072TM32B
spool and spring, exchange them to new

ones.
Θ After unloading hexagon socket bolts

(49, 50) and taking caps (47,48) away,
disassemble parts of counter balance
valve (37~46).
ö In disassembling counter balance valve,
be careful of figuring out the directions
such as the right or the left of finger.
If there is any abnormality in spool spring
check, exchange it to new one.
300072TM33
300072TM33A
300072TM33B
300072TM33C
300072TM33D
8-85
(14) Disassemble cylinder sub.
Η Disassemble set plate (25) and piston

(26) sub.
300072TM34
Θ Disassemble friction plate (27) and lee

plate (28) in cylinder block (21).
300072TM35
Ι Dismantle ball guide (24), spacer (23),

and cylinder spring (22).
300072TM36
300072TM36B
300072TM36A
8-86
3) ASSEMBLING TRAVEL MOTOR
(1) Assemble the sub of a turning axis.
Η After assembling bearing spacer (12) into

a turning axis (11), have cylinder roller
bearing (13) thermal-reacted.
a. In the thermal reaction of cylinder roller
bearing, use and induction heating
300072TM51
apparatus and adjust the temperature 300072TM51A
300072TM51B
as about 100˚C.
b. Deal moisturized copper part oil seal in
a turning axis without any damage of it.
(2) Assemble ring stop (14) with a plier.

ö Be careful of the direction of ring stop.
(The direction of round is the side of
bearing)
300072TM52
(3) Assemble valve casing sub.

Η Bond seven pieces of plug (2) in valve
casing (33) with standard torque.
After taping plug with seal taper and
Θ spread rock tight, assemble it.
ÂTightening torque : 7~11 kgfÂm
(50.63~79.5 lbfÂft)
300072TM53
8-87
(4) Compress pin (36) into.
ö Using a hammer, make the height of pin 5
mm from the a contact surface of valve
plate.
300072TM54
(5) Assemble needle bearing (34).
300072TM55
(6) Assemble seat (51), ball (52), stopper

(53), and hp plug (54) with O-ring (55),
respectively.
Η Be careful of the procedure and direction
of assembling seat and stopper. 300072TM56 300072TM56A
ÂTightening torque : 37 kgfÂm
(267.6 lbfÂft)
(7) Assemble hp plug (54) set up with O-ring

(55).
Â5sites
(267.6 lbfÂft)
300072TM57
8-88
(8) Bond orifice screw (38) on the right and
left side of spool c.b (37) with a standard
torque.
(50.63 lbfÂft)
300072TM58
(9) Insert hold spool c.b (37) and damper

check (39) into valve casing.
300072TM59 300072TM59A
300072TM59B 300072TM59C
(10)Bond cap R (47) and cap L (48) with

hexagon socket bolts (49, 50).
Η Remember not to exchange cap R, L
each other in assembling.
Tightening torque
ÂM12 : 100 kgfÂm (item 49)
ÂM10 : 67 kgfÂm (item 50)
300072TM60
(11)After fastening with torque, inser t

automatic plowing spool (04), spring (68)
and O-ring (69).
(542.4 lbfÂft)
300072TM61 300072TM61A
8-89
(12)Assemble swash road (60) inserted by
O-ring (61).
300072TM62
(13)Insert O-ring (32) into valve casing.
300072TM63
(14)Bond drain plug (30) inserted by O-ring

(31) with standard torque.
(723.3 lbfÂft)
300072TM64
(15)Assemble cylinder sub.

Η Assemble cylinder spring (22), spacer
(23), and spherical surface bush (24) into
cylinder (21).
Set the position of spline of spherical
surface bush and cylinder.
300072TM65
300072TM65A
300072TM65B
8-90
(16)Assemble friction plate (27) and separated
plate (28) into cylinder.
300072TM66
(17)After insert piston shoe (26) into set plate

(25), assemble it into cylinder.
300072TM67 300072TM67A
(18)Using jig, compress oil seal (73) into shaft

casing (01).
300072TM68
(19)Assemble the body of a motor.

Η Bond seven piece of plug (02) in shaft
casing plug with standard torque.
a. After taping plug with seal taper and
spread rock tight, assemble it. 300072TM69 300072TM69A
ÂTightening torque : 7~11 kgfÂm

(50.63~79.5 lbfÂft)
8-91
(20)Using a hammer and a handle, compress
pin (5, 6).
Η Pin (5) : Set the height as 10 mm from the
contact surface of a plate
supporter. - 2pieces. 300072TM70 300072TM70A
Pin (6) : Set the height as 19 mm from the

manufactured surface of shaft
casing. - 4pieces.
(21)Assemble sub of a turning axis.
300072TM71
(22)Assemble plate supporter (15) with M12

bolt.
ö Be careful of the direction of plate
supporter driven.
300072TM72
(23)Assemble plate (16) into plate supporter.

Η Spread grease in moisturized copper part
of plate.
Θ Confirm the soft movement of plate.
300072TM73
8-92
(24)Assemble stopper L (36) combined by
plowing piston (35) and O-ring (42).
300072TM74 300072TM74A
(25)Rotating dismantling and assembling jig

up to 90˚ make shaft from perpendicular
to horizontal.
ö Be careful that plate is not segregated
from plate supporter.
300072TM75
(26)Assemble cylinder sub.

ö Adjusting pin into holes of separated plate,
assemble it.
300072TM76
(27)Rotating dismantling and assembling jig

up to 90˚, make the direction of shaft from
the horizon to the perpendicular.
300072TM77
8-93
(28)Assemble piston ring (30), piston ring 252
(30) and 278 (31) into brake piston (29).
300072TM78
(29)Assemble brake piston into shaft casing.

ö Be careful of the direction of assembling
brake piston.
300072TM79
(30)Assemble brake spring (32).

ö Quantity : Spring-10pieces, Holes-
11pieces
ö Do not assemble on the top of brake
piston.
300072TM80
(31)Insert O-ring (69), after fastening orifice

screw (4) with standard torque.
ÂQuantity and size : (4) 2 pieces-͚1.0
(56)1pieces-͚1.5
ÂTightening torque : 7 kgfÂm (50.63 lbfÂft)
300072TM81
8-94
(32)After inserting valve plate (67) into valve
casing, bond it into shaft casing with
hexagon socket bolt (70).
Η Spread grease on the back side of valve
plate, in order for valve plate to be
adhered well.
Θ Use a crane in assembling it into valve
plate shaft casing.
Ι Set holes, ͚5, of valve plate heading
toward the port of the inlet and outlet of 300072TM82
valve casing.
Κ Spread grease in the side of plowing
spool of plowing spring in order that
plowing spring can not be detached.
(1736 lbfÂft)
ÂTightening torque : 180Ü10 kgfÂm
(1302Ü72.3 lbfÂft)
(33)Bond relief valve (57) with standard

torque.
300072TM83
(34)Unloosen four pieces of bolts (M20Ý50L)

fixing a motor and remove the motor away
from jig.
300072TM84
8-95
3. DISASSEMBLING REDUCTION UNIT
1) Preparation for disassembling
(1) The reduction units removed from
excavator are usually covered with mud.
Wash outside of propelling unit and dry it.
(2) Locate reducer in order for drain port to be
at the lowest level loosen taper screw plug
of drain port, and drain oil from reduction
gear.
ö While oil is still hot, inside of the unit
may be pressurized. 300078RD01
Take care of the hot oil gushing out of
the unit when loosening the plug.
(3) Mark for mating
Put marks on each mating parts when
disassembling so as to reassemble
correctly as before.
2) Setting reduction unit (or whole propelling
unit) on work stand for disassembling
(1) Remove hexagon socket head bolts (M10,
19) at 3 places from cover (17) almost
equally each other, and then install eye
bolts (M10).
Lift up the unit using them and place it on
work stand with cover upward.
ö Take great care not th pinch your hand
between parts while disassembling nor
let fall parts on your foot while lifting
them.
3) Removing cover
(1) Remove the rest of hexagon socket head
bolts(M10, 19) that secure ring gear.
Loosen all the socket bolts and then,
disassemble cover.
(2) As the cover(17) is adhered to ring gear
(14), dissemble ring gear (14) and cover
(17) by lightly hammering slantwise
upward using sharpen punch inserted
between the cover and ring gear.
8-96
4) Removing No.1 carrier sub assy
(1) Remove No.1 sun gear
ö Be sure to maintain it vertical with the
ground when disassembling No.1 sun
gear.
300078RD02
(2) Screw three eye bolt (M10, 15) in No.1

carrier and lift up and remove No.1 carrier
assy.
300078RD03
5) Removing No. 2 carrier sub assy

(1) Remove No.2 sun gear
gear.
300078RD04
(2) Screw three M10 eye bolt in No.2 carrier

and lift up and remove No.2 carrier assy.
300078RD05
8-97
6) Removing ring gear
(1) Remove hexagon socket head bolts(M14,
15) that secure ring gear and housing.
300078RD06
(2) As the ring gear (14) is adhered to

housing (3), disassemble ring gear (14) Ring gear
15
and housing (3) by lightly hammering
slantwise upward using sharpen punch Hammer
inserted between the ring gear and Housing
housing.
ö Carefully disassembling ring gear not
to make scratch on it.
2907A8RD01
(3) Screw three eye bolt (M10) in ring gear

and lift up and remove it.
Hoist
I-Bolt
Ring gear
Housing
2907A8RD02
8-98
7) Remove No.3 carrier sub assy
(1) Removing No.3 sun gear
gear.
300078RD09
(2) Screw three eye bolt (M10) in No.3 carrier

and lift up and remove No.3 carrier assy.
Hoist
#3 Carrier assy
Housing
2907A8RD03
8) Remove coupling
(1) Remove coupling
Housing Coupling
2907A8RD04
8-99
9) Remove motor ring
(1) Remove motor ring using hand.
300078RD12
10) Removing retainer & shim

(1) Remove hexagon socket (M12) head bolts
that retainer and motor.
(2) Remove retainer & shim.
300078RD13
11) Removing housing sub assy

(1) Screw eye bolt (M14) in housing and lift up
housing assembly including angular
bearing and floating seal. Hoist
12) Removing floating seal
(1) Lift up a piece of floating seal of motor Housing
side.
2907A8RD05
13) Dissembling housing assembly

(1) After turning housing, lift up a piece of
floating seal from housing and then
remove it.
ö Don't disassemble angular bearing.
300078RD15
8-100
14) Dissembling No.1 carrier
(1) Remove thrust ring (16) from carrier.
(2) Knock spring pin (89-6) fully into No.1 pin
(90-5).
(3) Remove planetary, thrust washer, No.1
pin, bearing from carrier.
15) Disassembling No.2,3 carrier

(1) Disassemble (14) carriers, using the same
method for No.1 carrier assembly. 300078RD15
8-101
6. ASSEMBLING REDUCTION GEAR
- General precautions
Clean every part by kerosene and dry them by air blow.
Surfaces to be applied by locktite must be decreased by solvent.
Check every part for any abnormals.
Each hexagon socket head bolt should be used with locktite No. 242 applied on its threads.
Apply gear oil slightly on each part before assembling.
Take great care not to pinch your hand between parts or tools while assembling nor let fall parts on
your foot while lifting them.
Inspection before reassembling

Thrust washer
ÂCheck if there are seizure, abnormal wear or uneven wear.
ÂCheck if wear is over the allowable limit.
Gears
ÂCheck if there are pitting or seizure on the tooth surface.
ÂCheck if there are cracks on the root of tooth by die check.
Bearings
ÂRotate by hand to see if there are something unusual such as noise or uneven rotation.
Floating seal
ÂCheck flaw or score on sliding surface or on O-rings.
8-102
1) Assembling No.1 carrier
(1) Put No.1 carrier (90-1) on a flat place. Pin 1
(2) Install No.1 needle bearing (90-3) into
Thrust washer 1
No.1 planetary gear (90-2), put 2 ea of
2 Planetary gear 1
No.1 thrust washer (90-4) on both sides of
1
bearing, and then install it into carrier.
(3) Install No.1 pin (90-5) into No.1 carrier 3
where the holes for No.1 pin (90-5) are to Bearing 1
be in line with those of No.1 carrier, and Spring pin
then, install spring pins into the holes. 2907A8RD06
(4) Caulk carrier holes as shown on the
picture.
(5) Assembly ring thrust (96) into carrier.
300078RD15
Caulk at two points
Install spring pin into the

hole after caulk
0.5
1.0 - 2.0
2907A8RD19
8-103
2) Assembling No.2 carrier Planetary gear 2
(1) Make No.2 planetary gear (89-2) vertical, Pin 2
Needle bearing 2
assemble 8-9 ea of No.2 needle (89-3), Assembly jig
and then, assemble the remaining No.2
needle by use of the assembly jig for No.2
pin (89-5).
(2) Remove out the assembly jig for No.2 pin
and assemble 2 ea of No.2 thrust washer
(89-4) into No.2 carrier (89-1).
(3) Insert No.2 pin (89-5) into carrier where 2907A8RD07
the holes of No.2 pin (89-5) are in line with
those of carrier.
Pin 2
(4) Hammer spring pin (89-6) to insert into
carrier hole and No.2 pin hole, and then,
caulk. Assemble 2 sets using the same Thrust washer 1
2
method.
Planetary gear 1
(5) Assemble ring thrust (98) into carrier.
1
3) Assembling No.3 carrier
(1) Assemble 4 sets, using the same method
3
for assembly of No.2 carrier. Bearing 1
Spring pin
2907A8RD08
4) Inst
Installing
alling floating seal
(1) Assemble floating seal into motor by use
Pressing jig
of pressing jig. Press
(2) Grease the contact parts for floating seal
which is assembled into motor. Floating seal
Housing
2907A8RD09
300078RD21
8-104
5) Assembling housing
(1) Heat housing at 60~70˚C while clearing it
out and then, assemble bearing. Main bearing
(2) Assemble floating seal into housing by
use of pressing jig as shown on the Housing Press
picture.
ground when assembling bearing and
floating seal.
2907A8RD10
Floating seal Pressing jig

Press
Housing
Main bearing
2907A8RD11
6) Installing housing assembly

(1) Install 2 ea of eye bolt (M14) into housing
assembly. Hoist
(2) Assemble housing into motor by use of
hoist and eye bolt.
ö Be sure to tighten eye bolt deep enough.
Housing
2907A8RD12
7) Installing main bearing

(1) Heat main bearing at 60~70˚C and then,
install. Main bearing
Housing
ground when assembling bearing.
2907A8RD13
8-105
8) Installing retainer (86) and shim (85)
(1) Measure clearance between main bearing
Retainer
and retainer by use of jig to decide the
Shim
thickness of shim and select and
appropriate shim, and then, assemble Housing
retainer.
(2) Apply locktite (#242) on hexagon socket
head bolt (M12), and then, bolt.
2907A8RD14
300078RD13
9) Installing motor ring

(1) Insert motor ring into motor to install.
Motor ring
Housing
2907A8RD15
10) Installing coupling

(1) Install coupling on spline of the motor.
Coupling
Housing
2907A8RD16
8-106
11) Installing No.3 carrier sub assy
(1) Install eye bolt(M10) on No.3 carrier
assembly.
(2) Lift No.3 carrier assembly and then, Hoist
assemble it into reducer. Carrier assy 3
ö Match it vertical with the spline of the
motor and the, slowly lower. Housing
2907A8RD17
12) Installing ring gear

(1) Apply three bond #1104 (Locktite #515)
on housing for ring gear without gap.
(2) Insert lock pin into housing hole.
(3) Install eye bolt (M12) on the tap for cover
of ring gear.
(4) Lift ring gear and then, assemble into
housing.
(5) Apply locktite to hexagon socket bolt
(M14) and then, bolt, having appropriate 300078RD30
torque.
300078RD31
300078RD06
8-107
13) Installing No.3 sun gear (88-7)
(1) Install snap ring (88-8) in No.3 sun
gear(88-7) by use if snap ring flier.
(2) Install No.3 sun gear on the spline of No.3
carrier, matching teeth of them.
300078RD32
300078RD09

(1) Install eye bolt (M10) on No.2 carrier
assembly.
(2) Lift No.2 carrier assembly and then, slowly
put it down on ring gear.
(3) Rotate planetary gear by hands and install
in ring gear.
300078RD05
8-108
15) Installing No.2 sun gear (89-7)
(1) Install snap ring (89-8) on No.2 sun gear
(89-7) by use of snap ring flier.
(2) Install No.2 sun gear on the spline of No.2
carrier and No.2 planetary gear, matching
teeth of them.
300078RD33
300078RD04

(1) Install eye bolt (M10) on No.1 carrier
assembly.
(2) Lift No.1 carrier assembly and then, put it
down on ring gear slowly.
(3) Rotate planetary gear by hands to install
on ring gear, matching their teeth.
300078RD03
17) In
Installing
stalling No.1 sun gear (91)
(1) Put down No.1 sun gear on No.1 carrier,
maintaining it vertical with spline of
coupling.
(2) Install No.1 sun gear on No.1 planetary
gear, matching their teeth.
300078RD02
8-109
18) Installing cover (97)
(1) Beat pad with plastic hammer, and press it
into the center of cover.
Pad Plastic hammer
(2) Apply three bond #104 (locktite #515) on
Cover
the ring gear for without gap.
(3) Put cover on ring gear, apply locktite
(#242) in hexagon socket head bolt (M10),
and then, bolt.
(4) Fill gear oil (8L) into drain port.
(5) Apply sealing tape (teflon) on PT3/4 plug
2908ARD18
and then, bolt.
300078RD35
8-110
GROUP 7 RCV LEVER

1) REMOVAL

(4) Loosen the socket bolt (1). 1
2
(5) Remove the cover of the console box.
(6) Disconnect pilot line hoses (3). 3
(7) Remove the pilot valve assembly (2).

※ When removing the pilot valve assembly,
check that all the hoses have been
21098RL01
disconnected.
2) INSTALL
to removal.
(2) Confirm the hydraulic oil level and check
8-112
1) STRUCTURE
23
25
26
24
22
21
9
19
20 16
17,27
18
14
11 15
8
7
28 10
6
13
5
12
4
3
1
2
Port 1,3 Port 2,4 300E2RL02
1 Case 8 Stopper 15 O-ring 22 Lock nut

2 Plug 9 Push rod 16 Rod seal 23 Handle assembly
3 Bushing 10 Spring 17 Plate 24 Handle bar
4 Spool 11 Push rod 18 Boot 25 Nut
5 Shim 12 Spring 19 Joint assembly 26 Boot
6 Spring 13 Spring seat 20 Swash plate 27 Spring pin
7 Spring seat 14 Plug 21 Adjusting nut 28 Bushing
8-113
(1) Tools
Tool name Remark
Allen wrench 6 B
22
Spanner
27
(+) Driver Length 150
(-) Driver Width 4~5

Torque
Part name Item Size
kgf·m lbf·ft
Plug 2 PT 1/8 3.0 21.7
Joint 19 M14 3.5 25.3
Swash plate 20 M14 5.0±0.35 36.2±2.5
Adjusting nut 21 M14 5.0±0.35 36.2±2.5
Lock nut 22 M14 5.0±0.35 36.2±2.5
8-114
3) DISASSEMBLY
(1) Clean pilot valve with kerosene.
※ Put blind plugs into all ports
(2) Fix pilot valve in a vise with copper (or
lead) sheets.
(3) Remove end of boot (26) from case (1)
and take it out upwards.
300E8RL01
※ For valve with switch, remove cord also

through hole of casing.
300E8RL02
(4) Loosen lock nut (22) and adjusting nut

(21) with spanners on them respectively,
and take out handle section as one body.
300E8RL03
(5) Remove the boot (18).
1408DA61
8-115
(6) Loosen adjusting nut (21) and swash
plate (20) with spanners on them
respectively, and remove them.
36078RL01
36078RL02
(7) Turn joint anticlockwise to loosen it,

utilizing jig (Special tool).
※ When return spring (10) is strong in force,
plate (17), plug (14) and push rod (11) will
come up on loosening joint.
Pay attention to this.
36078RL03
36078RL04
8-116
(8) Remove plate (17).
36078RL05
(9) When return spring (10) is weak in force,

plug (14) stays in casing because of
sliding resistance of O-ring.
※ Take it out with minus screwdriver.
Take it out, utilizing external periphery
groove of plug and paying attention not to
damage it by partial loading.
※ During taking out, plug may jump up due
to return spring (10) force.
36078RL06
Pay attention to this.
(10) Remove reducing valve subassembly

and return spring (10) out of casing.
※ Record relative position of reducing valve
subassembly and return springs.
36078RL07
(11) Loosen hexagon socket head plug(2) with

hexagon socket screw key.
36078RL08
8-117
(12) For disassembling reducing valve section,
stand it vertically with spool (4) bottom
placed on flat workbench. Push down
spring seat (7) and remove two pieces of
semicircular stopper (8) with tip of small
minus screwdriver.
※ Pay attention not to damage spool
surface.
※ Record original position of spring seat (7).
36078RL09
※ Do not push down spring seat more than
6mm.
(13) Separate spool (4), spring seat (7), spring

(6) and shim (5) individually.
※ Until being assembled, they should be
handled as one subassembly group.
36078RL10
(14) Take push rod (11) out of plug (14).
36078RL11
(15) Remove O-ring (15) and seal (16) from

plug (14).
Use small minus screwdriver or so on to
remove this seal.
36078RL12
8-118
36078RL13
(16) Remove lock nut (22) and then boot (26).
36078RL14
2507ARL10
8-119
(16) Cleaning of parts
① Put all parts in rough cleaning vessel
filled with kerosene and clean them
(rough cleaning).
※ If dirty part is cleaned with kerosene just
after putting it in vessel, it may be
damaged. Leave it in kerosene for a
while to loosen dust and dirty oil.
※ If this kerosene is polluted, parts will be
damaged and functions of reassembled
valve will be degraded.
Therefore, control cleanliness of
kerosene fully.
② Put parts in final cleaning vessel filled
with kerosene, turning it slowly to clean
them even to their insides (finish
cleaning).
※ Do not dry parts with compressed air,
since they will be damaged and/or rusted
by dust and moisture in air.
(17) Rust prevention of parts
Apply rust-preventives to all parts.
※ If left as they after being cleaned, they will
be rusted and will not display their
functions fully after being reassembled.
8-120
4) ASSEMBLY
(1) Tighten hexagon socket head plug (2) to
the specified torque.
※ Tighten two bolts alternately and slowly.
36078RL15
(2) Put shim (5), springs (6) and spring seat

(7) onto spool (4) in this order.
36078RL16
(3) Stand spool vertically with its bottom

placed on flat workbench, and with spring
seat pushed down, put two pieces of
semicircular stopper (8) on spring seat
without piling them on.
※ Assemble stopper (8) so that its sharp
edge side will be caught by head of spool.
Do not push down spring seat more than
6mm.
36078RL17
(4) Assemble spring (10) into casing (1).

Assemble reducing valve subassembly
into casing.
※ Assemble them to their original positions.
36078RL18
8-121
(5) Assemble O-ring (15) onto plug (14).
36078RL19
(6) Assemble seal (16) to plug (14).

※ Assemble seal in such lip direction as
shown below.
36078RL20
(7) Assemble push rod (11) to plug (14).

※ Apply working oil on push-rod surface.
36078RL21
(8) Assemble plug subassembly to casing.

※ When return spring is weak in force,
subassembly stops due to resistance of
O-ring.
36078RL22
8-122
(9) When return spring is strong in force,
assemble 4 sets at the same time,
utilizing plate (17), and tighten joint (19)
temporarily.
36078RL23
(10) Fit plate (17).
(11) Tighten joint (19) with the specified torque

to casing, utilizing jig.
36078RL24
(12) Assemble swash plate (20) to joint (19).

※ Screw it to position that it contacts with 4
push rods evenly.
※ Do not screw it over.
36078RL25
(13) Assemble adjusting nut (21), apply

spanner to width across flat of plate (20)
to fix it, and tighten adjusting nut to the
specified torque.
※ During tightening, do not change position
of disk.
36078RL26
8-123
(14) Fit boot (18) to plate.
1408DA61
(15) Fit boot (26) and lock nut (22), and handle
subassembly is assembled completely.
2507ARL10
36078RL27
(16) Pull out cord and tube through adjusting

nut hole provided in direction 60。to
120。from casing hole.
1408DA66
8-124
(17) Assemble bushing (27) to plate and pass
cord and tube through it.
※ Provide margin necessary to operation.
300E8RL04
(18) Determine handle direction, tighten lock

nut (22) to specified torque to fix handle.
300E8RL05
(19) Apply grease to rotating section of joint

and contacting faces of disk and push
rod.
300E8RL06
(20) Assemble lower end of bellows to casing.

(21) Inject volatile rust-preventives through all
ports and then put blind plugs in ports.
300E8RL07
8-125
GROUP 8 TURNING JOINT

1) REMOVAL

injury.
(4) Disconnect all hoses.
1
(5) Sling the turning joint assembly (1) and
remove the mounting bolt (2).
21078DA07
Weight : 55 kg (120 lb)
Tightening torque : 12.31.3 kgfm
(899.4 lbfft)
(6) Remove the turning joint assembly.
※ When removing the turning joint, check
that all the hoses have been disconnected.
2) INSTALL
to removal. 1
Take care of turning joint direction.
Assemble hoses to their original positions.
Confirm the hydraulic oil level and check
2
21078DA08
8-126
1) STRUCTURE
14 3
15 6
10
12 4
11 5
11
9
8
21098TJ01
1 Hub 6 Shim 11 Wear ring

2 Shaft 7 Slipper seal 12 Retainer ring
3 Cover 8 O-ring 13 Plug
4 Spacer 9 O-ring 14 Hexagon bolt
5 Shim 10 O-ring 15 Spring washer
8-127
2) DISASSEMBLY 14
Before the disassembly, clean the turning 15
joint.
3
(1) Remove bolts (14), washer (15) and cover
(3).
21078DA10
(2) Remove shim (6) and O-ring (10). 6

10
(3) Remove retainer ring (12), spacer (4) and
12
shim (5).
4
5
21078DA11
(4) Place hub (1) on a V-block and by using a Secure with hand
wood buffer at the shaft end, hit out shaft Wooden block
(2) to about 1/2 from the body with a
hammer.
※ Take care not to damage the shaft (2)
when remove hub (1) or rest it sideway.
V block
※ Put a fitting mark on hub (1) and shaft (2).
Work bench
8-14(3) (360-7)
(5) Remove six slipper seals (7) and O-ring 11

(9), two wear ring (11) from hub (1).
7
11
9
21078DA12
8-128
3) ASSEMBLY
※ Clean all parts.
※ As a general rule, replace oil seals and
O-ring.
※ Coat the sliding surfaces of all parts with
engine oil or grease before installing.
(1) Fix seven slipper seal (7) and O-ring (9), 11

two wear ring (11) to hub (1).
(2) Fit O-ring (8) to shaft (2). 7
11
9
1
21078DA12
(3) Set shaft (2) on block, tap hub (1) with a

plastic hammer to install. 2
21078DA13
(4) Fit shim (5), spacer (4) and retainer ring 6

(12) to shaft (2). 10
12
(5) Fit O-ring (10) to hub (1).
4
(6) Fit shim (6) to shaft (2).
5
21078DA11
8-129
(7) Install cover (3) to body (1) and tighten
14
bolts (14).
15
Torque : 10~12.5 kgfm
(72.3~90.4 lbfft) 3
21078DA10
8-130
GROUP 9 BOOM, ARM AND BUCKET CYLINDER

1) BUCKET CYLINDER
(1) Removal
※ Expand the arm and bucket fully, lower
the work equipment to the ground and
stop the engine.
※ Operate the control levers and pedals
pressure in the hydraulic piping. 13031GE18
Loosen the breather slowly to release

the pressure inside the hydraulic tank.
※ Escaping fluid under pressure can Bucket Cylinder
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
① Set block between bucket cylinder and Arm
arm.
Wooden block
29078CY001
② Remove bolt (2), nut (3) and pull out pin 2

(1).
※ Tie the rod with wire to prevent it from 3
coming out.
29078CY002
③ Disconnect bucket cylinder hoses (4)

and put plugs (5) on cylinder pipe. 5
29078CY003
8-130
④ Sling bucket cylinder assembly (8) and
8
remove bolt (6) then pull out pin (5).
⑤ Remove bucket cylinder assembly (8).
6 29078CY004
(2) Install
① Carry out installation in the reverse order
to removal.
When aligning the mounting position
of the pin, do not insert your fingers in
the pin hole.
※ Bleed the air from the bucket cylinder.
※ Confirm the hydraulic oil level and check
8-131
2) ARM CYLINDER
(1) Removal
stop the engine.
Loosen the breather slowly to release 13031GE18

※ Escaping fluid under pressure can
Fit blind plugs in the hoses after Arm cylinder
disconnecting them, to prevent dirt or
dust from entering.
① Set block between arm cylinder and
boom. Block
29078CY01
② Remove bolt (2) and pull out pin (1).

※ Tie the rod with wire to prevent it from
coming out.
29078CY02
③ Disconnect arm cylinder hoses (4) and 5

put plugs on cylinder pipe. 4
④ Disconnect greasing pipings (5).
29078CY03
8-132
⑤ Sling arm assembly (8) and remove bolt
(7) then pull out pin (6).
⑥ Remove arm cylinder assembly (8). 8
6 7
29078CY04
(2) Install
to removal.
the pin hole.
※ Bleed the air from the arm cylinder.
※ Confirm the hydraulic oil level and check
8-133
3) BOOM CYLINDER
(1) Removal
stop the engine.
Loosen the breather slowly to release 13031GE18
※ Escaping fluid under pressure can
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust 1
from entering.
① Disconnect greasing hoses (1).
② Sling boom cylinder assembly.
29078CY05
③ Remove bolt (4), pin stopper (5) and pull 4

out pin (2). 5
2
※ Tie the rod with wire to prevent it from
coming out.
4
5
50078CY11
④ Lower the boom cylinder assembly (6)

on a stand.
29078CY07
8-134
⑤ Disconnect boom cylinder hoses (7) and
put plugs on cylinder pipe.
29078CY08
⑥ Remove bolt (9) and pull out pin (8).

⑦ Remove boom cylinder assembly (6).
·Weight : 300 kg (660 lb) 6
8
9
29078CY09
(2) Install
to removal.
the pin hole.
※ Bleed the air from the boom cylinder.
※ Conformed the hydraulic oil level and
check the hydraulic oil leak or not.
8-135
1) STRUCTURE
(1) Bucket cylinder
9,10 6,7 8 4,5 23 31 30 3 22 11,12 1 2 13 14 17 16 15 18,19 20 21
Internal detail
32098BK01
1 Tube assembly 12 Back up ring 23 Hexagon socket head bol

2 Rod assembly 13 Cushion ring 24 Pin bushing
3 Gland 14 Piston 25 Pin bushing
4 DD2 bushing 15 Piston seal 26 Dust seal
5 Snap ring 16 Wear ring 27 Band assembly
6 Rod seal 17 Dust ring 28 Pipe assembly
7 Back up ring 18 O-ring 29 Pipe assembly
8 Buffer ring 19 Back up ring 30 O-ring
9 Dust wiper 20 Lock nut 31 Hexagon socket head bolt
10 Snap ring 21 Hexagon socket set screw
11 O-ring \ 22 O-ring
8-136
(2) Arm cylinder
9,10 6,7 8 4,5 23 34 33 3 22 11,12 1 2 13 14 17 16 15 18,19 20 21
Internal detail
26,27,28,29
30 32 31 24,25
32098AM01
1 Tube assembly 13 Cushion ring 25 Dust seal

2 Rod assembly 14 Piston 26 Check valve
3 Gland 15 Piston seal 27 Coil spring
4 DD2 bushing 16 Wear ring 28 O-ring
5 Snap ring 17 Dust ring 29 Plug
6 Rod seal 18 O-ring 30 Band assembly
7 Back up ring 19 Back up ring 31 Band assembly
8 Buffer ring 20 Lock nut 32 Pipe assembly
9 Dust wiper 21 Hexagon socket set screw 33 O-ring
10 Snap ring 22 O-ring 34 Hexagon socket head bolt
11 O-ring 23 Hexagon socket head bolt
12 Back up ring 24 Pin bushing
8-137
(3) Boom cylinder
9,10 6,7 8 4,5 23 30 29 3 22 11,12 1 2 13 14 17 16 15 18,19 20 21
Internal detail
24,25 27 26 28 30 24,25
32098BO01
1 Tube assembly 11 O-ring 21 Hexagon socket set screw

2 Rod assembly 12 Back up ring 22 O-ring
3 Gland 13 Cushion ring 23 Hexagon socket head bolt
4 DD2 bushing 14 Piston 24 Pin bushing
5 Snap ring 15 Piston seal 25 Dust seal
6 Rod seal 16 Wear ring 26 Band assembly
7 Back up ring 17 Dust ring 27 Pipe assembly
8 Buffer ring 18 O-ring 28 Pipe assembly
9 Dust wiper 19 Back up ring 29 O-ring
10 Snap ring 20 Lock nut 30 Hexagon socket head bolt
8-138
(1) Tools
Tools Remark
6
8 B
Allen wrench
14
17
7
Spanner
8
(-) Driver Small and large sizes

Torque
Part name Item Size
kgfÂm lbfÂft
Bucket cylinder 23 M18 32.0Ü3.0 232Ü21.7
Socket head bolt Boom cylinder 23 M12 46.0Ü5.0 333Ü7.2
Arm cylinder 23 M22 63.0Ü6.0 457Ü43.4
Bucket cylinder 31 M12 9.4Ü1.0 68.0Ü7.2
Socket head bolt Boom cylinder 30 M12 9.4Ü1.0 68.0Ü7.2
Arm cylinder 34 M12 9.4Ü1.0 68.0Ü7.2
Bucket cylinder 20 - 100Ü10.0 723Ü72.3
Lock nut Boom cylinder 20 - 100Ü10.0 723Ü72.3
Arm cylinder 20 - 150Ü15.0 1085Ü108
Bucket cylinder 14 - 150Ü15.0 1085Ü108
Piston Boom cylinder 14 - 150Ü15.0 1085Ü108
Arm cylinder 14 - 200Ü20.0 1447Ü145
8-139
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
ö Procedures are based on the bucket
cylinder.
Η Hold the clevis section of the tube in a
vise.
ö Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
Θ Pull out rod assembly (2) about 200

mm (7.1 in). Because the rod assembly
is rather heavy, finish extending it with air
pressure after the oil draining operation.
m
0m
20
21078DA30
Ι Loosen and remove socket bolts (23) of

Hexagon
the gland in sequence. socket wrench 23
ö Cover the extracted rod assembly (2)
with rag to prevent it from being
Turn counter
accidentally damaged during operation.
clockwise
Cover here
with rag
2
32098DA01
Κ Draw out cylinder head and rod assembly

together from tube assembly (1). Lift
ö Since the rod assembly is heavy in this
case, lift the tip of the rod assembly (2)
with a crane or some means and draw it Full straight
sideways
out. However, when rod assembly (2)
has been drawn out to approximately
two thirds of its length, lift it in its center
Oil pan
to draw it completely.
21078DA32
8-140
Note that the plated surface of rod
assembly (2) is to be lifted. For this
reason, do not use a wire sling and
others that may damage it, but use a
strong cloth belt or a rope.
Λ Place the removed rod assembly on a

wooden V-block that is set level.
ö Cover a V-block with soft rag. Rod assy
Wooden block
32098DA02
(2) Remove piston and cylinder head 13 14 18 19 20 21

Η Loosen sochet set screw (21) and
remove lock nut (20).
ö Since lock nut (20) is tightened to a high
torque, use a hydraulic and power
wrench that utilizers a hydraulic cylinder,
to remove the lock nut (20).
Θ Remove piston assembly (14), back up
ring (19), and O-ring (18).
2907A8CY02
Ι Remove the cylinder head assembly

Plastic
from rod assembly (2). hammer
ö If it is too heavy to move, move it by
Lift with a crane
striking the flanged part of cylinder head
with a plastic hammer.
Pull straight
ö Pull it straight with cylinder head
assembly lifted with a crane.
Exercise care so as not to damage the
lip of rod bushing (4) and packing
21078DA35
(5,6,7,8,9,10) by the threads of rod
assembly (2).
8-141
(3) Disassemble the piston assembly 17 16 15 16 17
Η Remove wear ring (16).
Θ Remove dust ring (17) and piston seal
(15).
ö Exercise care in this operation not to
damage the grooves.
2907A8CY03
(4) Disassemble cylinder head assembly

Η Remove back up ring (12) and O-ring 10 9 6 7 8 4 5 12 11
(11).
Θ Remove snap ring (10), dust wiper (9).
Ι Remove back up ring (7), rod seal (6),
buffer ring (8) and snap sing (5).
ö Exercise care in this operation not to
damage the grooves.
ö Do not remove seal and ring, if does not
21078DA36
damaged.
8-142
3) ASSEMBLY
(1) Assemble cylinder head assembly
ö Check for scratches or rough surfaces if
found smooth with an oil stone.
Η Coat the inner face of gland (3) with
hydraulic oil.
21078DA37
Θ Coat dust wiper (9) with grease and fit Press here
dust wiper (9) to the bottom of the hole of (Straight down)
dust seal. Metal
At this time, press a pad metal to the 9
metal ring of dust seal.
Ι Fit snap ring (10) to the stop face.
8-157(2)
Κ Fit back up ring (7), rod seal (6) and

buffer ring (8) to corresponding grooves,
in that order.
ö Coat each packing with hydraulic oil Wrong Right
before fitting it.
ö Insert the backup ring until one side of it
is inserted into groove.
8-157(3)
ö Rod seal (6) has its own fitting direction.

Push bar
Therefore, confirm it before fitting them.
ö Fitting rod seal (6) upside down may
damage its lip. Therefore check the
correct direction that is shown in fig.
21078DA38
8-143
Λ Fit back up ring (12) to gland (3).
ö Put the backup ring in the warm water of 11
30~50˚C .
12
Μ Fit O-ring (11) to gland (3).
21078DA39
(2) Assemble piston assembly

ö Check for scratches or rough surfaces.
If found smooth with an oil stone.
Η Coat the outer face of piston (14) with
hydraulic oil.
8-158(2)
Θ Fit piston seal (15) to piston.

ö Put the piston seal in the warm water of 15
60~100˚C for more than 5 minutes.
ö After assembling the piston seal, press
its outer diameter to fit in.
2907A8CY04
Ι Fit wear ring (16) and dust ring (17) to 17 16 15 16 17

piston (14).
14
2907A8CY05
8-144
(3) Install piston and cylinder head
Η Fix the rod assembly to the work bench. Cylinder head assembly
Θ Apply hydraulic oil to the outer surface of Rod assembly
rod assembly (2), the inner surface of
piston and cylinder head.
Ι Insert cylinder head assembly to rod
assembly.
21078DA40
Κ Insert cushion ring (13) to rod assembly.

ö Note that cushion ring (13) has a 13
direction in which it should be fitted.
Insert
8-159(2)
Λ Fit piston assembly to rod assembly. Piston assembly

ÂTightening torque : 100Ü10.0 kgfÂm
(723Ü72.3 lbfÂft)
50078CY09
Μ Fit lock nut (20) and tighten the set screw

20 21
(21).
ÂTightening torque :
Item kgfÂm lbfÂft
Bucket 20 100Ü10 723.3Ü72.3
Boom 21 5.4Ü0.5 391Ü3.6
21 150Ü15 1085Ü108
Arm
22 5.4Ü0.5 39.1Ü3.6
50078CY10
8-145
(3) Overall assemble Fix with a bar
Η Place a V-block on a rigid work bench.
Mount the tube assembly (1) on it and Lift
fix the assembly by passing a bar
through the clevis pin hole to lock the
assembly. Straight
Θ Insert the rod assembly in to the tube
assembly, while lifting and moving the
rod assembly with a crane. Appply liquid packing
21078DA41
ö Be careful not to damage piston seal by
thread of tube assembly.
Ι Match the bolt holes in the cylinder head
flange to the tapped holes in the tube Turn clockwise
assembly and tighten socket bolts to a Apply loctite
specified torque.
ö Refer to the table of tightening torque.
Place rag
21078DA42
8-146
GROUP 10 UNDERCARRIAGE
1. TRACK LINK
1) REMOVAL
(1) Move track link until master pin is over
front idler in the position put wooden block Master pin
as shown.
(2) Loosen tension of the track link.
※ If track tension is not relieved when the
grease valve is loosened, move the
machine backwards and forwards.
(3) Push out master pin by using a suitable
tool.
Block
8-161(1)
(4) Move the machine slowly in reverse, and

lay out track link assembly (1).
※ Jack up the machine and put wooden
block under the machine.
※ Don't get close to the sprocket side as the
track shoe plate may fall down on your
feet.
1
8-161(2)
2) INSTALL
to removal.
Adjust the tension of the track link. 90 ~ 110
21074OP14
8-147
2. CARRIER ROLLER Frame
1) REMOVAL
Grease
(1) Loosen tension of the track link. valve
8-162(1)
(2) Jack up the track link height enough to

permit carrier roller removal.
Jack Carrier roller
8-162(2)
(3) Loosen the lock nut (1).

1 Carrier
(4) Open bracket (2) with a screwdriver, push roller
2
out from inside, and remove carrier roller
assembly.
Weight : 48 kg (88 lb)
8-162(3)
2) INSTALL
to removal.
8-148
3. TRACK ROLLER Frame
1) REMOVAL
(1) Loosen tension of the track link. Grease
valve
8-163(1)
(2) Using the work equipment, push up track

frame on side which is to be removed.
※ After jack up the machine, set a block
under the unit.
90-110
8-163(2)
(3) Remove the mounting bolt (1) and draw

out the track roller (2). 1 2
·Weight : 54 kg (119lb)
8-163(3)
2) INSTALL
(1) Carry out installation in the reverse order to
removal.
8-149
4. IDLER AND RECOIL SPRING
1) REMOVAL
(1) Remove the track link.
For detail, see removal of track link
link.
8-164(1)
(2) Sling the recoil spring (1) and pull out idler
and recoil spring assembly from track
frame, using a pry. 1
·Weight : 457 kg (1010 lb)
8-164(2)
(3) Remove the bolts (2), washers (3) and

separate idler from recoil spring.
2, 3
8-164(3)
2) INSTALL
to removal.
※ Make sure that the boss on the end face
of the recoil cylinder rod is in the hole of
the track frame.
8-164(4)
8-150
3) DISASSEMBLY AND ASSEMBLY OF IDLER
(1) Structure
5
1
2
2
7
5
6
7
4
4
3
6
29078ID01
1 Shell 4 O-ring 7 Spring pin

2 Bushing 5 Seal assembly 8 Plug
3 Shaft 6 Bracket
8-151
(2) Disassembly Press
① Remove plug and drain oil.
② Draw out the spring pin (7), using a
press.
7 8-166(1)
③ Pull out the shaft (2) with a press.

Press
④ Remove seal (5) from shell (1) and
bracket (6).
⑤ Remove O-ring (4) from shaft.
3
8-166(2)
⑥ Remove the bushing (2) from idler, using

a special tool.
※ Only remove bushing if replacement is
necessity.
2
8-166(3)
8-152
(3) Assembly
※ Before assembly, clean the parts.
※ Coat the sliding surfaces of all parts with 1 2 Press
oil.
① Cool up bushing (2) fully by some dry ice
and press it into shell (1).
Do not press it at the normal temperature,
or not knock in with a hammer even after
the cooling.
8-167(1)
② Coat O-ring (4) with grease thinly, and

install it to shaft (3).
4
③ Insert shaft (3) into bracket (6) and drive
in the spring pin (7). 3
8-167(2)
④ Install seal (5) to shell (1) and bracket (6).

5
8-167(3)
⑤ Install shaft (3) to shell (1).

3 1
8-167(4)
8-153
⑥ Install bracket (6) attached with seal (5).
8-168(1)
⑦ Knock in the spring pin (7) with a

6 7 1
hammer.
8-168(2)
⑧ Lay bracket (6) on its side.

6
Supply engine oil to the specified level,
and tighten plug.
8-168(3)
8-154
4) DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING
(1) Structure
36078UC02
1 Body 6 Lock plate 11 Dust seal

2 Tie bar 7 Bolt 12 Rod assembly
3 Spring 8 Spring washer 13 Grease valve
4 Bracket 9 Rod seal 14 Stopper tube
5 Lock nut 10 Back up ring 15 Spring pin
8-155
(2) Disassembly
Η Apply pressure on spring (3) with a
press.
ö The spring is under a large installed load.
This is dangerous, so be sure to set
properly.
·Spring set load : 19012 kg (41826 lb)
Θ Remove bolt (7), spring washer (8) and
lock plate (6).
Ι Remove lock nut (5).
Take enough notice so that the press
which pushes down the spring, should
not be slipped out in its operation.
Κ Lighten the press load slowly and
remove bracket (4) and spring (3).
36078UC03
Λ Remove rod (12) from body (1).

Μ Remove grease valve (13) from rod (12).
36078UC04
Ν Remove rod seal (9), back up ring (10)

and dust seal (11).
36078UC05
8-156
(3) Assembly
Η Install dust seal (11), back up ring (10)
and rod seal (9) to body (1).
ö When installing dust seal (11) and rod
seal (9), take full care so as not to
damage the lip.
36078UC05
Θ Pour grease into body (1), then push in

rod (12) by hand.
After take grease out of grease valve
mounting hole, let air out.
ö If air letting is not sufficient, it may be
difficult to adjust the tension of crawler.
Ι Fit grease valve (13) to rod (12).
·Tightening torque : 13.0Ü1.0 kgfÂm
(94Ü7.2 lbfÂft)
36078UC06
Κ Install spring (3) and bracket (4) to body

(1).
Λ Apply pressure to spring (3) with a press
and tighten lock nut (5).
ö Apply sealant before assembling.
ö During the operation, pay attention
specially to prevent the press from
slipping out.
36078UC07
8-157
Μ Lighten the press load and confirm the
set length of spring (3).
Ν After the setting of spring (3), install lock
plate (6), spring washer (8) and bolt (7).
32078UC08
8-158
GROUP 11 WORK EQUIPMENT
1. STRUCTURE
A
A
SECTION A SECTION B SECTION C
29078WE01
8-160
1) BUCKET ASSEMBLY
(1) Removal
① Lower the work equipment completely to
ground with back of bucket facing down. A
B
8-174(1)
② Remove nut (1), bolt (2) and draw out the

pin (A).
45078AT01
③ Remove nut (3), bolt (4) and draw out the

pin (B).
45078AT02
(2) Install
to removal.
the pin hole.
※ Adjust the bucket clearance.
For detail, see operation manual.
8-174(4)
8-161
2) ARM ASSEMBLY
(1) Removal
※ Loosen the breather slowly to release
penetrated the skin causing serious
injury.
① Remove bucket assembly.
For details, see removal of bucket 8-175(1)
assembly.
② Disconnect bucket cylinder hose (1).
Fit blind plugs in the piping at the
chassis end securely to prevent oil 5
from spurting out when the engine is
4
started.
③ Sling arm cylinder assembly, remove
spring, pin stopper and pull out pin.
※ Tie the rod with wire to prevent it from 4
coming out.
④ For details, see removal
emoval of arm cylinder
21078DA16
assembly.
Place a wooden block under the cylinder
and bring the cylinder down to it.
⑤ Remove bolt (2), plate (3) and pull out
the pin (4) then remove the ar m
assembly. Crane
·Weight : 1160 kg (2560 lb)
※ When lifting the arm assembly, always lift
the center of gravity. 2, 3, 4
8-175(3)
(2) Install
① Carry out installation in the reverse
order to removal.
When lifting the arm assembly, always
lift the center of gravity.
※ Bleed the air from the cylinder.
8-162
3) BOOM CYLINDER
(1) Removal
① Remove arm and bucket assembly.
For details, see removal of arm and
bucket assembly.
② Remove boom cylinder assembly from
boom.
For details, see removal of arm cylinder
assembly. 8-176(1)
③ Disconnect head lamp wiring.

④ Disconnect bucket cylinder hose (2) 1
and arm cylinder hose (1). 2
※ When the hose are disconnected, oil
may spurt out.
⑤ Sling boom assembly (3). 1
21078DA45
⑥ Remove bolt (4), plate (5) and pull out

Crane
the pin (6) then remove boom assembly.
·Weight : 2540 kg (5600 lb)
※ When lifting the boom assembly always
4, 5, 6
3
8-176(3)
(2) Install
to removal.
When lifting the arm assembly, always
※ Bleed the air from the cylinder.
21078DA46
8-163
Group 1 Introduction guide --------------------------------------------------------------------------------------------- 9-1

Group 2 Engine system -------------------------------------------------------------------------------------------------- 9-2
Group 3 Electric system ------------------------------------------------------------------------------------------------- 9-4
Group 4 Hydraulic system ---------------------------------------------------------------------------------------------- 9-6
Group 6 Structure ------------------------------------------------------------------------------------------------------------ 9-11
Group 7 Work equipment ------------------------------------------------------------------------------------------------ 9-15
GROUP 1 INTRODUCTION GUIDE
1. This section shows bolt specifications and

standard torque values needed when
mounting components to the machine.
2. Use genuine Hyundai spare parts.
We expressly point out that Hyundai will not
accept any responsibility for defects resulted
from non-genuine parts.
In such cases Hyundai cannot assume
liability for any damage.
※ Only metric fasteners can be used and
incorrect fasteners may result in machine
damage or malfunction.
※ Before installation, clean all the
components with a non-corrosive cleaner.
Bolts and threads must not be worn or 29079CM00
damaged.
9-1
GROUP 2 ENGINE SYSTEM
ENGINE AND ACCESSORIES MOUNTING
6 A
3
Muffler 2
6
3
1
4
2
6
Fan
A
3
Engine
4
3
1 1
Accel actuator
Air cleaner
3309S9CM01
·Tightening torque
Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft

1 M 8×1.25 2.5±0.5 18.1±3.6 4 M12×1.75 12.8±3.0 92.6±21.7
2 M10×1.5 6.9±1.4 49.9±10.1 5 M14×2.0 9.8±0.9 70.8±6.5
3 M12×1.75 10.0±2.0 72.3±14.5 6 M24×3.0 90±7.0 651±51
9-2
COOLING SYSTEM AND FUEL TANK MOUNTING
4
Pre filter
Hyd tank 5
Air compressor 2
Fuel tank
Air con
idle pully 6
Air con
pully
7 7
9
9
3
Condenser
Screen
6 10
Needle
valve 7
Radiator 2
2 1
Oil cooler
Resevoir tank
6
6
7
8
Shroud
Fan guard
3309S9CM02
·Tightening torque
1 M 6×1.0 0.5±0.2 3.6±1.45 6 M10×1.5 6.9±1.4 49.9±10.1

2 M 8×1.25 2.5±0.5 18.1±3.6 7 M12×1.75 12.8±3.0 92.6±21.7
3 M 8×1.25 1.3±0.2 9.4±1.45 8 M16×2.0 29.7±4.5 215±32.5
4 M 8×1.25 4.3±0.2 31.1±1.45 9 M20×2.5 57.9±8.7 419±62.9
5 M10×1.25 5.0±0.2 36.1±1.45 10 - 1.8±0.1 13.0±0.7
9-3
GROUP 3 ELECTRIC SYSTEM
ELECTRIC COMPONENTS MOUNTING 1 (CLUSTER TYPE 1)
Start relay
Heater relay
3
Work lamp
4 Alternator
Rear view camera

2
2
CLUSTER TYPE 2 3
Back buzzer
2 A
MCU
3 2
3
Fuel filler 2
pump 1
3
Work lamp
2 Washer tank
Battery
2
Horn
Battery relay 3 1
3
1
Work lamp 2
DETAIL A DETAIL B
3309S9CM03
·Tightening torque
1 M 6×1.0 1.05±0.2 7.6±1.45 3 M10×1.5 6.9±1.4 49.9±10.1

2 M 8×1.25 2.5±0.5 18.1±3.6 4 M12×1.75 12.8±3.0 92.6±21.7
9-4
ELECTRIC COMPONENTS MOUNTING 2
VIEW A
Beacon lamp Electric box
3
1 Fuse box
Wiper
motor
TO FRAME HARNESS
Cluster
1
Cluster
B 1
DC-DC converter Radio & USB player
2
2
2
DETAIL B(TYPE 1) DETAIL B(TYPE 2)
3309S9CM04
·Tightening torque
1 M 6×1.0 1.05±0.2 7.6±1.45 3 M10×1.5 6.9±1.4 49.9±10.1

2 M 8×1.25 2.5±0.5 18.1±3.6
9-5
GROUP 4 HYDRAULIC SYSTEM
HYDRAULIC COMPONENTS MOUNTING 1
Level gauge 3 Solenoid valve

Air breather 3
3
3 Drain filter
Main control valve

5
Main pump
Hydraulic tank
A
5
Bracket-MCV mtg
10 7
Swing motor
4 9
RCV-LH
3
Terminal assy
1
VIEW A
RCV-RH 3 6
3
Cross 3
Main pump
housing
1
8
3
3
Coupling
8
3309S9CM05
·Tightening torque
1 M 6×1.0 1.05±0.2 7.6±1.45 6 M20×2.5 42±4.5 304±32.5
2 M10×1.5 4.8±0.3 34.7±2.2 7 M20×2.5 46±5.1 333±36.9
3 M10×1.5 6.9±1.4 49.9±10.1 8 M20×2.5 46.5±2.5 336±18.1
4 M12×1.75 12.3±1.3 88.9±9.4 9 M20×2.5 58.4±6.4 422±46.2
5 M12×1.75 12.8±3.0 92.5±21.6 10 M20×2.5 57.9±8.7 419±62.9
9-6
Double acting attachment piping

Travel motor(RH)
6
5
4
Stop
valve
3 Turning joint
1 D/acting Travel motor(LH)
3 way joint
3
4
4
Solenoid valve
2 D/acting
hose joint
Accumulator
RCV-pedal
D/acting single pedal
Check valve
2
Filter line EPPR

valve
Cartridge
3009S9CM06
·Tightening torque
1 M 8×1.25 4.05±0.8 29.3±5.8 4 M12×1.75 12.8±3.0 92.6±21.7

2 M10×1.5 6.9±1.4 49.9±10.1 5 M14×2.0 19.6±2.9 142±20.9
3 M12×1.75 12.3±1.3 88.9±9.4 6 M24×3.0 84±8.0 723±72.3
9-7
BOOM CYLINDER
1 3
1
1
4
4
3 4
3
3
7 1 5
ARM CYLINDER BUCKET CYLINDER
3309S9CM07
·Tightening torque
1 M10×1.5 3.2±0.3 23.1±2.2 5 M16×2.0 23±2.0 166±14.5
2 M 8×1.25 2.7±0.3 19.5±2.2 6 M18×2.5 32±3.0 232±21.7
3 M12×1.75 5.5±0.6 39.8±4.3 7 M20×2.5 46±5.0 333±36.2
4 M12×1.75 9.4±1.0 68.0±7.2
9-8
GROUP 5 UNDERCARRIAGE
UNDERCARRIAGE MOUNTING
ADJUST COMPONENT 1
Rod
Swing bearing
1
9
3 9
5
9
Idler
Cover
7 Idler
1 Cover
2 Carrier roller
8 Track chain
2
2 Adjust
component
Track roller
Track guard
6
Travel motor
Sprocket
3309S9CM08
·Tightening torque
1 M10×1.5 6.9±1.4 49.9±10.1 5 M16×2.0 29.7±4.5 215±32.5
2 M12×1.75 12.8±3.0 92.6±21.7 6 M20×2.5 57.9±6.0 419±43.4
3 M12×1.75 15±0.5 108±3.6 7 M22×1.5 115±5.0 831±36
4 M16×2.0 29.7±3.0 215±21.7 8 M24×3.0 100±10 723±72.3
9-9
UNDERCARRIAGE MOUNTING (HIGH WALKER)
2
2
Idler
2
1
Roller
4
Track guard
1
Full track guard type 5
3309S9CM09
·Tightening torque
1 M10×1.5 6.9±1.4 49.9±10.1 4 M20×2.5 57.9±8.6 419±62.2

2 M12×1.75 12.2±1.3 88.2±9.4 5 M24×3.0 100±15 723±108
3 M20×2.5 51±4.0 369±28.9 6 - - -
9-10
GROUP 6 STRUCTURE
CAB AND ACCESSORIES MOUNTING
Sun roof assy
2
4
Cab
1
4 5 Air vent cover
4
1
Sliding
door wa 2
Bracket latch assy
5
Plate
non slip
3
2
Striker
Side door
Latch assy
3309S9CM10
·Tightening torque
1 M 6×1.0 0.49±0.1 3.5±0.7 4 M10×1.5 6.9±1.4 49.9±10.1

2 M 8×1.25 2.5±0.5 18.1±3.6 5 M12×1.75 12.8±3.0 92.6±21.7
3 M10×1.5 4.7±0.9 34±6.5
9-11
CAB INTERIOR MOUNTING
1
Seat 1
Storage box 1
1
3
3
Console
box(RH)
3
1 Trim-rear mid
K 4
3
Seat base
Console
5 K box(LH)
1
Safety lever
3
4 Pedal
Slide rail 1
6
Pedal bracket
4
Travel
lever
Viscous
Foot rest mount
Foot rest
bracket Bottom plate
4
3309S9CM11
·Tightening torque
1 M 6×1.0 0.49±0.1 3.5±0.7 4 M10×1.5 6.9±1.4 49.9±10.1

2 M 8×1.25 4.05±0.8 29.3±5.8 5 M10×1.5 8.27±1.7 59.8±12.3
3 M 8×1.25 2.5±0.5 18.1±3.6 6 M16×2.0 29.7±4.5 215±32.5
9-12
COWLING MOUNTING
3 3 Engine hood
Pump hood
K 3
Pump screen
3
1
1 1
3 3
Engine hood
3 support
3 3
3
Tank cover 3
3 3
Screen
3
K
3
Air cleaner hood
3 3
3
MCV hood
Side cover(RH) Engine hood

support
3 3
3
1 1
2 Bottom
support
3
3
3
1
1
Side cover(LH)
3 3
3309S9CM12
·Tightening torque
Item Size kgf·m lbf·ft
1 M8×1.25 2.5±0.5 18.1±3.6
2 M10×1.5 6.9±1.4 49.9±10.1
3 M12×1.75 12.8±3.0 92.6±21.7
9-13
COUNTERWEIGHT AND COVERS MOUNTING
Counterweight
3
Handle 3
1 1
Hyd tank
Fuel tank
1 cover
Upper frame
3
3 1
Fuel tank
1
1
4
2 Tool box 1
Rad under cover
2 Pump under cover
Hyd tank under cover
1
1
Fuel tank under cover
1 Engine under cover
MCV under cover 1

1
Cab under cover
3309S9CM13
·Tightening torque
1 M10×1.5 6.9±1.4 49.9±10.1 3 M12×1.75 12.8±3.0 92.6±21.7
2 M 8×1.25 2.5±0.5 18.1±3.6 4 M36×3.0 308±46 2228±333
9-14
GROUP 7 WORK EQUIPMENT
Arm cylinder
rod pin
2
Arm cylinder
Bucket cylinder
head pin
1
2 Boom cylinder
rod pin
1
Bucket cylinder
1 Arm pin 2
Boom
Bucket
2 control link
Bucket cylinder Arm cylinder Boom cylinder
rod pin head pin head pin Boom pin
Boom 1
2 2 cylinder 2
3 Bucket
Side cutter(RH)
2
1
Bucket control
rod pin
Cover plate
Side cutter(LH)
3309S9CM14
·Tightening torque
1 M16×2.0 29.7±4.5 215±32.5 3 M22×2.5 81.9±16.1 592±116
2 M20×2.5 57.9±8.7 419±62.9
9-15

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CONTENTS

Group 1 Safety Hints ------------------------------------------------------------------------------------------------------- 1-1

SECTION 2 STRUCTURE AND FUNCTION

Group 1 Pump Device ----------------------------------------------------------------------------------------------------- 2-1

SECTION 3 HYDRAULIC SYSTEM

Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------ 3-1

SECTION 4 ELECTRICAL SYSTEM

Group 1 Component Location ---------------------------------------------------------------------------------------- 4-1

SECTION 5 MECHATRONICS SYSTEM

Group 1 Outline --------------------------------------------------------------------------------------------------------------- 5-1

Group 1 Before Troubleshooting ------------------------------------------------------------------------------------ 6-1

SECTION 7 MAINTENANCE STANDARD

Group 1 Operational Performance Test ------------------------------------------------------------------------- 7-1

SECTION 8 DISASSEMBLY AND ASSEMBLY

Group 1 Precaution --------------------------------------------------------------------------------------------------------- 8-1

Group 1 Introduction guide --------------------------------------------------------------------------------------------- 9-1

2. Convert 550mm into inches.

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

Liter to U.K. Gallon 1ℓ = 0.21997 U.K.Gal

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

Be careful of slippery conditions on platforms,

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

AVOID POWER LINES

MOVE AND OPERATE MACHINE SAFELY

OPERATE ONLY FORM OPERATOR'S SEAT

PARK MACHINE SAFELY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

Store flammable fluids away from fire hazards.

ILLUMINATE WORK AREA SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HIGH PRESSURE FLUIDS

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

Use only recommended replacement parts.

REPLACE SAFETY SIGNS

LIVE WITH SAFETY

Battery box Fuel tank Hydraulic tank Main pump

Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight

Bucket cylinder Connecting link Idler Carrier roller Sprocket